Isuzu 2000 Trooper Workshop Manual
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Isuzu 2000 Trooper Workshop Manual

Isuzu 2000 Trooper Workshop Manual

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Table of Contents

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WORKSHOP MANUAL
TROOPER
(UX)
FOREWORD
This manual includes special notes, important points, service
data, precautions, etc. that are needed for the maintenance,
adjustments, service, removal and installation of vehicle
components.
All information, illustrations and specifications contained in
this manual are based on the latest product information
available at the time of publication.
All rights are reserved to make changes at any time without
notice.
Arrangement of the material is shown in the table of contents
on the right-hand side of this page. A black spot on the first
page of each section can be seen on the edge of the book
below each section title. These point to a more detailed table
of contents preceding each section.
This manual applies to 2000 models.
SECTION
TABLE OF CONTENTS
Click
GENERAL INFORMATION
0A
General Information
0B
Maintenance and Lubrication
HEATING, VENTILATION AND AIR CONDITIONING
1A
HVAC Systems
STEERING
2A
Power Assisted System
SUSPENSION
3C
Front Suspension
3D
Rear Suspension
3E
Wheel and Tire System
DRIVELINE/AXLE
4A1
Differential (Front)
4A2
Differential (Rear)
4B1
Driveline Control System (SHIFT ON THE FLY)
4B2
Driveline Control System (TOD)
4C
Drive Shaft System
4D1
Transfer Case (Standard Type)
4D2
Transfer Case (TOD)
BRAKE
5A
Brake Control System
5B
Anti-Lock Brake System
5C
Power-Assisted Brake System
5D
Parking Brake System
ENGINE
6A
Engine Mechanical
6B
Engine Cooling
6C
Engine Fuel
6D1
Engine Electrical
6D2
Ignition System
6D3
Starting and Charging System
6E
Driveability and Emissions
6F
Engine Exhaust
6G
Engine Lubrication
6H
Engine Speed Control System
6J
Induction
TRANSMISSION
7A
Automatic Transmission
7A1
Transmission Control System
7B
Manual Transmission
7C
Clutch
BODY AND ACCESSORIES
8A
Lighting System
8B
Wiper/Washer System
8C
Entertainment
8D
Wiring System
8E
Meter and Gauge
8F
Body Structure
8G
Seats
8H
Security and Locks
8I
Sun Roof/Convertible Top
8J
Exterior/Interior Trim
RESTRAINTS
9A
Seat Belt System
9J
Supplemental Restraint System (SRS)
9J1
Restraint Control System
CONTROL SYSTEM
10A
Cruise Control System
HOME

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Summary of Contents for Isuzu 2000 Trooper

  • Page 1 HOME SECTION TABLE OF CONTENTS Click GENERAL INFORMATION General Information Maintenance and Lubrication HEATING, VENTILATION AND AIR CONDITIONING WORKSHOP MANUAL HVAC Systems STEERING Power Assisted System TROOPER SUSPENSION Front Suspension (UX) Rear Suspension Wheel and Tire System DRIVELINE/AXLE Differential (Front) Differential (Rear) Driveline Control System (SHIFT ON THE FLY) Driveline Control System (TOD)

  • Page 2: Table Of Contents

    The SRS system equipped vehicle can be identified efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 1. “AIR BAG” warning light on the instrument panel. 7. Used cotter pins, plastic clips, gaskets, O–rings, oil 2.

  • Page 3: Illustration Arrows

    0A–2 GENERAL INFORMATION Illustration Arrows Arrows are designed for specific purposes to aid your understanding of technical illustrations. Arrow Type Application Arrow Type Application D Ambient/Clean air flow Front of vehicle D Cool air flow D Gas other than ambient air Up Side D Hot air flow D Ambient air mixed...

  • Page 4: Identification

    GENERAL INFORMATION 0A–3 Identification Vehicle Identification Number (VIN) This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle. 905RY00002 F00RY00002...
  • Page 5 0A–4 GENERAL INFORMATION Engine Serial Number Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode The gasoline engine serial number is stamped on the left switch. rear lower area of the cylinder block above the starter. 240RW012 F06RW001 Transmission Serial Number...

  • Page 6: Theft Prevention Standard

    GENERAL INFORMATION 0A–5 Theft Prevention Standard The 11 major components listed below will be marked with 17 digit V.I.N. at the stage of production. In addition its service parts will be marked with manufacturer’s trade mark, “R” mark and “DOT” mark. INDICATION Reference COMPONENT...
  • Page 7 0A–6 GENERAL INFORMATION Anti Theft Stamping/Label/Plate Location The stamping, label and plate locations are indicated by arrows in the illustration below. NOTE: A. VIN plate locations for production. B. Stamping locations for service parts. Engine 901RW195 Manual Transmission (AR–5) 901RX021...
  • Page 8 GENERAL INFORMATION 0A–7 Automatic Transmission (THM) 901RW197 Body 901RW113 Legend (6) Fender (3) Engine Hood (7) Rear Quarfer Panel (4) Front Door (8) Front Bumper (5) Rear Door...
  • Page 9 0A–8 GENERAL INFORMATION Body 901RW114 Legend (10) Back Door Right Side (9) Back Door Left Side (11) Rear Bumper...
  • Page 10 GENERAL INFORMATION 0A–9 Body Label Instructions Do not peel off the masking tape until completion of paint work when replacing these parts, as the tape is affixed on the label attached to service parts for body of the anti–theft component. NOTE: Be sure to pull off the masking tape after paint work has been completed.

  • Page 11: Lifting Instructions

    0A–10 GENERAL INFORMATION Lifting Instructions CAUTION: D If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage. D When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or...
  • Page 12 GENERAL INFORMATION 0A–11 Lifting Point; Front Lifting Point; Rear D When using a floor jack, lift on the center of the skid D Position the floor jack at the center of the rear axle plate. case when lifting the vehicle. 545RS001 420RS002 Supportable Point;...
  • Page 13 0A–12 GENERAL INFORMATION Supportable Point; Rear D Position the chassis stands at the bottom of the rear axle case. 420RS001...

  • Page 14: Standard Bolts Torque Specifications

    GENERAL INFORMATION 0A–13 Standard Bolts Torque Specifications The torque values given in the following table should be applied where a particular torque is not specified. Strength Class Strength Class Refined Non-Refined Bolt Identification Bolt Diameter Pitch (mm) M 6X1.0 4—8 (3—6) 5—10 N·m (4—7 lb ft) —...

  • Page 15: Abbreviations Charts

    0A–14 GENERAL INFORMATION Abbreviations Charts Exh — Exhaust ° F — Degrees Fahrenheit List of automotive abbreviations which may be used Fed — Federal (All States Except Calif.) in this manual FF — Front Drive Front Engine A — Ampere(s) FL —...

  • Page 16: Service Parts Identification Plate

    GENERAL INFORMATION 0A–15 N — Newtons TVRS — Television & Radio Suppression NA — Natural Aspirated TVV — Thermal Vacuum Valve NC — Normally Closed TWC — Three Way Catalytic Converter N·M — Newton Meters 3 A/T — Three Speed Automatic Transmission/Transaxle NO —...
  • Page 17 SECTION MAINTENANCE AND LUBRICATION 0B–1 TROOPER GENERAL INFORMATION MAINTENANCE AND LUBRICATION CONTENTS Maintenance Schedule List ....0B–1 Lubricant Viscosity Chart ....0B–9 Explanation of Complete Vehicle Maintenance Recommended Liquid Gasket...
  • Page 18 MAINTENANCE AND LUBRICATION 0B–2 Mileage Only Items...
  • Page 19 MAINTENANCE AND LUBRICATION 0B–3 Mileage/Months...
  • Page 20 MAINTENANCE AND LUBRICATION 0B–4...

  • Page 21: Maintenance Schedule List

    MAINTENANCE AND LUBRICATION 0B–5 Explanation of Complete Vehicle Valve Clearance Adjustment Maintenance Schedule Incorrect valve clearance will result in increased engine noise and reduced engine output. Brief explanations of the services listed in the preceding Retorque the camshaft bearing cap bolts before checking Maintenance Scheduled are presented below.
  • Page 22 MAINTENANCE AND LUBRICATION 0B–6 Battery fluid level normal highway speeds means a wheel balancing is needed. Check tire pressure when the tires are “cold” Check fluid level in the battery. (include the spare). Maintain pressure as shown in the tire placard, which is Fluid Leak Check located on the driver’s door lock pillar.
  • Page 23 MAINTENANCE AND LUBRICATION 0B–7 crank. The starter should crank only when the clutch pedal is fully depressed. Accelerator Linkage Lubrication Lubricate the accelerator pedal fulcrum pin with chassis grease. Steering and Suspension Inspection Inspect the front and rear suspension and steering system for damaged, loose or missing parts or signs of wear.

  • Page 24: Recommended Fluids And Lubricants

    MAINTENANCE AND LUBRICATION 0B–8 Recommended Fluids and Lubricants USAGE FLUID/LUBRICANT Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil chart on the following page for proper viscosity) Mixture of water and good quality ethylene glycol base Engine coolant type antifreeze.

  • Page 25: Lubricant Viscosity Chart

    MAINTENANCE AND LUBRICATION 0B–9 Lubricant Viscosity Chart Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following table. Oil Viscosity Chart for Gasoline Engine 905RT011...
  • Page 26 MAINTENANCE AND LUBRICATION 0B–10 Oil Viscosity Chart for Manual Transmission and Transfer Case B00RW002 Oil Viscosity Chart for Front Axle B00RW003...

  • Page 27: Recommended Liquid Gasket

    Three Bond 1281 Three Bond Water Base Three Bond 1141E Three Bond For Engine Repairs Three Bond 1104 Three Bond Belco Bond 4 Isuzu Solvent For Engine Repairs Belco Bond 401 Isuzu Belco Bond 402 Isuzu LOCTITE 515 Loctite Anaerobic...

  • Page 28: Recommended Thread Locking Agents

    MAINTENANCE AND LUBRICATION 0B–12 Recommended Thread Locking Agents LOCTITE Type LOCTITE Color LOCTITE 242 Blue LOCTITE 262 LOCTITE 271 Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry.

  • Page 29: Maintenance Service Data

    MAINTENANCE AND LUBRICATION 0B–13 Maintenance Service Data Service Data and Specifications ENGINE Valve clearance (cold) Intake 0.28 0.05 mm (0.011 in) Exhaust 0.3 0.05 mm (0.015 in) Spark plug type K16PR-P11/PK16PR11/RC10PYP4 Spark plug gap 1.05 mm (0.04 in) CLUTCH Clutch pedal free play 5-15 mm (0.197-0.591 in) BRAKE Brake pedal free play...
  • Page 30 SECTION HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–1 TROOPER HEATING, VENTILATION AND AIR CONDITIONING (HVAC) HVAC SYSTEMS CONTENTS Service Precaution ..... . 1A–3 Center Vent, Drive Side Vent and Associated Parts...
  • Page 31 1A–2 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Removal ......1A–60 Full Automatic Air Conditioner Parts Configuration .

  • Page 32: Heating And Ventilation System

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...
  • Page 33 1A–4 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 840RS004 Legend (8) Duct (1) Side Defroster Hose (9) Heater Unit (2) Vent Box (10) Rear Heater Duct (3) Upper Center Vent Box (11) Lap Vent Nozzle (4) Lower Center Vent Box (12) Vent Box (5) Blower Assembly (13) Side Defroster Hose (6) Control Lever Assembly...
  • Page 34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–5 Control Lever Assembly The vehicle has cable-type-control to control the mode The fan control is used to control the amount of air sent and temperature of the heater unit and the mode door for out by the resistor at four levels from “LOW”...
  • Page 35 1A–6 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Ventilation Set “AIR SOURCE SELECT LEVER” to “FRESH” The blower fan also serves to deliver fresh outside air to position and turn on the blower fan. Heating can be done the vehicle interior to assure adequate ventilation. in this lever position, sending in fresh air from outside.
  • Page 36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–7 Air Select Knob The air select knob allows you to direct heated air into the Selecting this mode allows air conditioning system to work when the fan switch is turned to on position, passenger compartment through different outlets.

  • Page 37: Wiring Diagram

    1A–8 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Wiring Diagram D01RS005...

  • Page 38: Diagnosis

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–9 Diagnosis Heating Cycle diagnosis Condition Possible cause Correction No heating or insufficient heating. Blower motor does not run or runs Refer to “FAN CONTROL LEVER improperly. (FAN SWITCH) DIAGNOSIS”. Engine coolant temperature is low. Check engine coolant...
  • Page 39 1A–10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Fan Control Lever (Fan Switch) Diagnosis Current flows to the blower motor through the heater and For the inspection of the relays, switches and units in the A/C relay (B-36) to activate the rotation of the blower each table, refer to “INDIVIDUAL INSPECTION”...
  • Page 40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–11 Chart “A” Blower Motor Dose Not Run Step Action Is relay (B-36) OK? Go to Step 2 Replace Is fuse C-19 (25A) OK? Go to Step 3 Replace Is resistor OK? Go to Step 4 Replace Is fan control knob OK? Replace control...

  • Page 41: Individual Inspection

    1A–12 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart “E” Blower Motor Dose Not Run At High Position Step Action Is resistor OK? Go to Step 2 Replace Is fan control knob (Fan Switch) OK? Open circuit between Chassis side connector terminal No.
  • Page 42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–13 Fan switch Resistor terminals Resistance position with continuity 2.4 m 1 — 2 0.90 m 2 — 4 0.28 m 2 — 6 2 — 3 — Fan Control Knob (Fan Switch) 1. Check for continuity between the terminals of the fan switch.

  • Page 43: Removal

    1A–14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Unit Heater Unit and Associated Parts 860RY00005 Legend (7) Heater Unit Assembly (1) Instrument Panel Assembly (8) Center Ventilation Lower Duct (2) Instrument Panel Center Bracket (9) Driver Lap Vent Nozzle (3) Resistor (10) Water Hose (4) Duct (11) Electro Thermo Connector (With A/C)

  • Page 44: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–15 8. Remove evaporator assembly (A/C only). D Refer to Evaporator Assembly in this section. 9. Remove instrument panel center bracket. D Refer to Cross Beam Assembly in Body and Accessories section. 10. Remove rear heater duct. 11.

  • Page 45: Heater Core And / Or Mode Door

    1A–16 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Core and / or Mode Door Disassembled View 860RS001 Legend (4) Heater Unit (1) Case (Temperature Control) (5) Case (Mode Control) (2) Mode Door (6) Heater Core (3) Duct Removal 4. Remove heater unit. D Refer to Heater Unit in this section.

  • Page 46: Inspection

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–17 7. Remove case (Temperature control). Separate two 9. Pull out the mode door while raising up the catch of halves of core case. the door lever. 860RS002 860RS004 8. Remove heater core (1). Inspection Check for foreign matter in the heater core, stains or core fin damage.

  • Page 47: Heater Mode Control Link Unit

    1A–18 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Mode Control Link Unit Disassembled View 860RS005 Legend (4) Clip (1) Case (Mode Control) (5) Door Lever (2) Heater Unit (6) Rod (3) Mode Sub-lever (7) Washer and Mode Main Lever Removal 1.

  • Page 48: Heater Temperature Control Link Unit

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–19 Installation 2. After installing the link unit, check to see if the link unit operates correctly. To install, follow the remove steps in the reverse order, noting the following points: 1. Apply grease to the mode sub-lever and to the abrasive surface of the heater unit.

  • Page 49: Blower Assembly

    1A–20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Blower Assembly Blower Assembly and Associated Parts 873RY00003 Legend (5) Blower Assembly (1) Electro Thermo Connector (6) Duct (2) Blower Motor Connector (7) Evaporator Assembly (A/C only) (3) Resistor Connector (8) Heater Unit (4) Dash Side Trim Panel (RH) (9) Instrument Panel Assembly Removal...

  • Page 50: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–21 Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Adjust the control lever assembly cables. D Refer to Control Lever Assembly in this section. Blower Link Unit and / or Mode door Disassembled View 873RS001 Legend...

  • Page 51: Installation

    1A–22 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 4. Remove lower case. 5. Separate the upper case and slit the lining parting face with a knife. 873RS002 6. Pull out the mode door while lifting up the catch of door lever. 7.

  • Page 52: Blower Motor

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–23 Blower Motor Blower Motor and Associated Parts 873RS004 Legend (4) Fan (1) Blower Motor Connector (5) Blower Motor (2) Blower Motor Assembly (6) Attaching Screw (3) Clip Removal Installation To install, follow the removal steps in the reverse order. 1.

  • Page 53: Rear Heater Duct, Defroster Nozzle And Ventilation Duct

    1A–24 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Rear Heater Duct, Defroster Nozzle and Ventilation Duct Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts 874RS017 Legend (6) Center Console (1) Center Defroster Nozzle (7) Rear Heater Duct (2) Side Defroster Nozzle (8) Driver Lap Duct (3) Side Ventilation Duct (9) Cross Beam Assembly...

  • Page 54: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–25 10. Remove side defroster nozzle. 11. Remove center defroster nozzle. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching.

  • Page 55: Control Lever Assembly And / Or Control Cable

    1A–26 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Control Lever Assembly and / or Control Cable Control Lever Assembly, Control Cable and Associated Parts 865RS011 Legend (7) Attaching Screws (1) Instrument Panel Passenger Lower Cover (8) Control Lever Assembly Assembly (9) Mode Control Link Connection (2) Glove Box (10) Front Console Assembly (3) Fan Switch and Air Conditioning Switch...

  • Page 56: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–27 8. Remove attaching screws. D Remove the four attaching screws. 865RS009 10. Remove control lever assembly. 11. Remove control cable. 865RS010 9. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. Installation To install, follow the removal steps in the reverse order, noting the following points:...

  • Page 57: Control Panel Illumination Bulb

    1A–28 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D Air source control cable. 2. Connect the control cable at the “COLD” position of the temperature control link of the 1. Slide the control lever to the left (“CIRC” heater unit and secure it with the clip. position).

  • Page 58: Resistor And Associated Parts

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–29 Resistor Resistor and Associated Parts 874RW005 Legend (5) Front Console (1) Glove Box (6) Lower Cluster (2) Duct (Heater only) (7) Instrument Panel Passenger Lower Cover Assembly (3) Resistor Connector (4) Resistor Removal Installation To install, follow the removal steps in the reverse order.

  • Page 59: Air Conditioning System

    1A–30 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Air Conditioning System General Description Air Conditioning Refrigerant Cycle Construction C01RS003 Legend (9) Condenser (1) Electronic Thermostat (10) Compressor (2) Evaporator Core (11) Magnetic Clutch (3) Evaporator Assembly (12) Mode (HEAT) Control Door (4) Temperature Sensor (13) Temp.
  • Page 60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–31 evaporator vaporizes readily. The liquid refrigerant This vehicle is equipped with six-cylinder axle plate removes the required quantity of heat (latent heat of compressor (1). vaporization) from the air around the evaporator core The specified amount of the compressor oil is 240cc cooling fins and rapidly vaporizes.
  • Page 61 1A–32 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) The refrigerant line connection has a bolt at the block joint, for easy servicing. The condenser assembly (6) is located in front of the radiator. It provides rapid heat transfer from the refrigerant to the cooling fins. 875RW004 Pressure Switch The pressure switch (Dual pressure switch) (4) is...
  • Page 62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–33 Expansion Valve Evaporator This expansion valve (1) is an external pressure type and The evaporator cools and dehumidifies the air before the it is installed at the evaporator intake port. air enters the passenger compartment. High-pressure The expansion valve converts the high pressure liquid liquid refrigerant flows through the expansion valve (2) refrigerant sent from the receiver/drier to a low pressure...
  • Page 63 1A–34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) A characteristic of the sensor is that the resistance Refrigerant Line decreases as the temperature increases and the Restriction in the refrigerant line will be indicated by: resistance increases as the temperature decreases. 1.
  • Page 64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–35 Air Conditioning Parts 852RW009 Legend (7) Condenser Assembly (1) Liquid Line (High-Pressure Pipe) (8) Drive Belt (2) O-ring (9) Relay (3) Compressor (10) Drain Hose (4) Discharge Line (High-Pressure Hose) (11) Suction Line (Low-Pressure Hose) (5) Pressure Switch (12) Evaporator Assembly (6) Receiver Drier...
  • Page 65 1A–36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Wiring Diagram D08RW254...
  • Page 66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–37 D08RX003...
  • Page 67 1A–38 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D08RW256...

  • Page 68: Diagnosis

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–39 Diagnosis Air Conditioning Cycle Diagnosis Condition Possible cause Correction No cooling or insufficient cooling. Magnetic clutch does not run. Refer to “Magnetic Clutch Diagnosis” in this section. Compressor is not rotating properly. Adjust the drive belt to the specified Drive belt is loose or broken.
  • Page 69 1A–40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Checking The Refrigerant System With Manifold Gauge Since Refrigerant-134a (HFC-134a) is used in the air conditioning system in this vehicle, be sure to use manifold gauges, charging hoses and other air conditioning service tools for HFC-134a when checking the refrigerant system.
  • Page 70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–41 Connect The Manifold Gauge Low-pressure hose (LOW) — Suction side High pressure hose (HI) — Discharge side 901RS137 Legend (1) Low Side (2) High Side Condition Possible cause Correction Discharge (High Gauge) Pressure Condenser clogged or dirty.
  • Page 71 1A–42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition Possible cause Correction Discharge (High Gauge) Pressure Restriction caused by debris or Check system for restriction and Abnormally Low. moisture in the receiver/drier. replace the receiver/drier. Frost or dew on refrigerant line before and after the receiver/drier or expansion valve, and low pressure gauge indicates vacuum.
  • Page 72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–43 Condition Possible cause Correction Suction (Low Gauge) and Discharge Excessive refrigerant in system. Discharge recover (High Gauge) Pressure Abnormally refrigerant, the Recharge to the High. specified amount. Insufficient cooling. Condenser clogged or dirty. Clean the condenser fins.
  • Page 73 1A–44 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Magnetic Clutch Diagnosis D08RX004 When the air conditioning switch and the fan control knob flows through the thermostat and the compressor relay to (fan switch) are turned on with the engine running, current activate the magnetic clutch.
  • Page 74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–45 The air conditioning can be stopped by turning off the air in the prearranged conditions to reduce the engine load conditioning switch or the fan control knob (fan switch). which is being caused by the rise in the engine coolant However, even when the air conditioning is in operation, temperature, and the acceleration of the vehicle, etc.
  • Page 75 1A–46 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Magnetic Clutch Does Not Run (Cont’d) Step Action Check to see if battery voltage is present at chassis side Power train connector terminal No. C1-B14. control module (PCM) defective. Is there a battery voltage? Refer to Open circuit between No.

  • Page 76: Individual Inspection

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–47 Individual Inspection Heater And A/C (B-36), Thermostat (X-5) And Compressor (X-7) Relay Fan Control Knob (Fan Switch) And Air 1. Disconnect relays and check for continuity and Conditioning (A/C) Switch resistance between relay terminals. 1.

  • Page 77: General Repair Procedure

    1A–48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D When removing and replacing any parts which Pressure Switch require discharging the refrigerant circuit, the 1. Disconnect pressure switch connector and check for operations described in this section must be continuity between pressure switch side connector performed in the following sequence: terminals (1) and (2).
  • Page 78 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–49 CAUTION: Compressor (PAG) oil to be used varies Insert the nut into the union. according to the compressor model. Be sure to apply First, tighten the nut by hand as much as possible, then oil specified for the model of compressor.
  • Page 79 1A–50 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Leak Check Inspection of refrigerant leak Therefore, it is most important to repair refrigerant leak when there is any leak found. Refrigerant leak may cause an adverse effect not only on the performance and durability of each component of the air-conditioner, but also on the global atmosphere.
  • Page 80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–51 3. If the leak is still present, discharge and recover the WARNING: refrigerant from the system. D SHOULD HFC-134A CONTACT YOUR EYE(S), 4. Replace the O-rings. CONSULT A DOCTOR IMMEDIATELY. D O-rings cannot be reused. Always replace with new D DO NOT RUB THE AFFECTED EYE(S).
  • Page 81 1A–52 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Recycling 8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the Recycle refrigerant recovered J-39500 gauge manifold pressure is at 750 mmHg (30 inHg), (ACR :HFC-134a Refrigerant Recovery / Recycling / close both hand valves.
  • Page 82 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–53 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle. 4. Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle.
  • Page 83 1A–54 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Checking The A/C System 1. Run the engine and close all the vehicle doors. 2. Turn A/C switch “ON”, set the fan switch to its highest position. 3. Set the air source lever to “CIRC”, set the temperature lever to the full cool position.

  • Page 84: Compressor Assembly

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–55 Compressor Assembly Compressor Assembly and Associated Parts 852RW010 Legend (3) Refrigerant Line Connector (1) Compressor Bracket (4) Compressor (2) Seal Washer (5) Drive Belt Removal 2. Discharge and recover refrigerant D Refer to Refrigerant Recovery in this section. 1.

  • Page 85: Installation

    1A–56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 4. Remove drive belt. 4. Connect magnetic clutch harness connector. D Move drive belt tensioner to loose side using wrench then remove drive belt. 850RY00001 Legend (1) Auto Tensioner (2) Idle Pulley (3) Cooling Fan Pulley (4) Drive Belt (5) Power Steering Oil Pump (6) Air Conditioner Compressor...

  • Page 86: Condenser Assembly

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–57 Condenser Assembly Condenser Assembly and Associated Parts 875RY00005 Legend (4) Radiator Grille (1) Refrigerant Line (5) Engine Hood Front End Stay (2) Pressure Switch Connector (6) Condenser Assembly (3) Front Bumper Assembly Removal Installation 1.

  • Page 87: Receiver / Drier

    1A–58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D Be sure to apply new compressor oil to the O-rings 4. Install engine hood front end stay. when connecting the refrigerant line. 5. Install front bumper assembly. 3. Connect pressure switch connector. 6.

  • Page 88: Pressure Switch

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–59 Pressure Switch Pressure Switch and Associated Parts 875RY00006 Legend (2) Pressure Switch (1) Pressure Switch Connector (3) Radiator Grille Removal Installation To install, follow the removal steps in the reverse order, 1. Disconnect the battery ground cable. noting the following point: 2.

  • Page 89: Evaporator Assembly

    1A–60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Evaporator Assembly Evaporator Assembly and Associated Parts 874RT002 Legend (5) Instrument Panel Passenger Lower Cover Assembly (1) Resistor and Electronic Thermostat Connector (6) Glove Box (2) Drain Hose (7) Front Console Assembly (3) Refrigerant Line (8) Lower Cluster Assembly (4) Passenger Knee Bolster Reinforcement (9) Evaporator Assembly...

  • Page 90: Electronic Thermostat, Evaporator Core And/Or Expansion Valve

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–61 9. Disconnect drain hose. 1. To install a new evaporator assembly, add 50cc (1.7 fl. oz.) of new compressor oil to the new core. 10. Disconnect refrigerant line. D Use a back-up wrench when disconnecting and 2.

  • Page 91: Installation

    1A–62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. Remove evaporator assembly. D Refer to Evaporator Assembly in this section. 4. Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7.

  • Page 92: Air Conditioning Switch And Illumination Bulb 1A-63

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–63 6. Be sure to install the sensor and the insulator on the 8. Tighten the refrigerant lines to the specified torque. place where they were before. Refer to Main Data and Specifications for Torque Specifications in this section.

  • Page 93: Refrigerant Line

    1A–64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Line Refrigerant Line and Associated Parts 852RY00013 Legend (4) Discharge Line (High Pressure Hose) (1) Clip and Clamp (5) Air Cleaner (2) Suction Line (Low Pressure Hose) (6) Radiator Grille (3) Liquid Line (High-Pressure Pipe) (7) Suction Line (Low-Pressure Pipe) Removal 7.

  • Page 94: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–65 D When removing the refrigerant line connecting part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. Installation To install, follow the removal steps in the reverse order, noting the following points: 1.

  • Page 95: Main Data And Specifications

    1A–66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Main Data And Specifications General Specifications HEATER UNIT Temperature control Reheat air mix system Capacity 4.3 kw (3,700 Kcal./hr.) Air flow 280 m#/hr HEATER CORE Type Plate and corrugate fin type Element dimension 171 mm (6.7 in.) 161 mm (6.3 in.) 25 mm (0.98 in.)
  • Page 96 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–67 Torque Specifications 852RW004 874RX016...

  • Page 97: Compressor

    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.
  • Page 98 This PAG lubricant should then be discarded and an equal amount of new PAG lubricant added to the compressor. The service compressor is shipped without PAG oil. When service procedures require, use only Isuzu approved PAG oil.

  • Page 99: Metric Thread Size Information

    1A–70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Metric Thread Size Information Compressor to mounting bracket bolts (Front) Compressor shaft 1.5 – 6H 1.25 – 6H Compressor to mounting bracket bolts (Rear) Internal hub-clutch drive assembly 1.25 – 6H 1.5 – 6H Suction-discharge port screw 1.5 –...

  • Page 100: Compressor Clutch Rotor And/Or Bearing

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–71 installer is held and the center screw is rotated, the 7. Remove installer J-33013-B, check for proper key will wedge and will break the clutch hub. positioning of the shaft key (even or slightly above the clutch hub).

  • Page 101: Compressor Clutch Coil

    1A–72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. Position puller crossbar J-8433-1 on the puller pilot 5. Install rotor and bearing assembly retainer ring, using J-33023-A and assemble the two J-33026 through snap ring pliers . bolts and washers through the puller bar slots and 6.

  • Page 102: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–73 Installation 1. Place the clutch coil assembly (1) on the front head with the terminals positioned at the “marked” location. 2. Place the J-33024 clutch coil installer over the internal opening of the clutch coil housing and align installer with the compressor front head.

  • Page 103: Compressor Shaft Seal

    1A–74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Compressor Shaft Seal Service Precaution Seal Leak Detection When replacing the shaft seal assembly, pressure relief A shaft seal should not be changed because of small valve or control switches, it will be necessary to recover amounts of oil found on an adjacent surface but only after the refrigerant.

  • Page 104: Cleaning

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–75 7. Remove and discard the seal seat O-ring (2) from the 2. Insert O-ring installer J-33011 into compressor neck using O-ring remover J-9553-01. compressor neck until the installer “bottoms”. Lower the moveable slide of the O-ring installer to release the O-ring into the seal O-ring lower groove (The compressor neck top groove is for the shaft seal retainer ring.) Rotate the installer to seat the O-ring...

  • Page 105: Compressor Pressure Relief Valve

    1A–76 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 6. Remove any excess oil resulting from installing the 8. Reinstall compressor belt and tighten bracket. new seal parts from the shaft and inside the 9. Evacuate and charge the refrigerant system. compressor neck. 7.

  • Page 106: Contamination Of Compressor Oil

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–77 1. Perform oil return operation. (Component parts to be (Amount of Oil) 2. Discharge and recover the refrigerant and remove the installed) compressor. Evaporator 50 cc (1.7 fl. oz.) 3. Drain the compressor oil and measure the extracted Condenser 30 cc (1.0 fl.
  • Page 107 1A–78 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 14. Attach the compressor to the J-34992 holding fixture and mount the compressor in a vise so that the compressor will be in a horizontal position and the shaft can be turned with a wrench. 15.

  • Page 108: Special Tools

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–79 Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J-33013-B J-8433-3 Hub and Clutch Drive Forcing Screw Plate Asm. remover J-33026 J-33025 Compressor Holding Clutch Coil Installer Fixture Adapter J-33024 J-33023-A Clutch Coil Installer Puller Pilot...
  • Page 109 1A–80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) TOOL NO. ILLUSTRATION TOOL NAME J-34614 Shaft Seal Protector J-39893 Pressure Testing Connector...

  • Page 110: Automatic Air Conditioning System

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–81 Automatic Air Conditioning System General Description off the compressor and switch the blow port as well as switching between the fresh air intake and interior air Using a variety of sensors, this automatic heater and air circulation.

  • Page 111: Refrigerant Line And Associated Parts

    1A–82 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Line and Associated Parts 852RY00002 Legend (7) Condenser Assembly (1) Liquid Line (High Pressure Pipe) (8) Drive Belt (2) O – Ring (9) Compressor (3) Discharge Line (High Pressure Hose) (10) Drain Hose (4) Pressure Switch (11) Suction Line (Low-Pressure Hose) (5) Receiver Drier...

  • Page 112: Circuit Diagram

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–83 Circuit Diagram 6VE1 Engine D08RY00109...
  • Page 113 1A–84 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D08RY00110...
  • Page 114 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–85 D08RY00155...
  • Page 115 1A–86 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D08RY00147...
  • Page 116 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–87 D08RY00148...

  • Page 117: Functions And Features

    1A–88 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Functions and Features the system. Self-diagnosis function Automatic interior temperature control The self-diagnosis function turned on from the panel This function enables to maintain the interior switch makes your troubleshooting easier (for detail temperature at the level specified from the of this function, refer to the section titled temperature control switch despite of changes in...

  • Page 118: Automatic Air Conditioner Block Diagram

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–89 Automatic Air Conditioner Block Diagram F01RY00006...

  • Page 119: Control Panel Layout

    1A–90 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Control Panel Layout 865RY00024 Legend (5) Intake Switch (1) Auto Switch (6) Fan Switch (2) Mode Switch (7) Air Conditioning Switch (3) DEF/FOOT Switch (8) Temperature Control Knob (4) DEF Switch...

  • Page 120: Air Control Functions

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–91 Air Control Functions C01RY00004 Legend (7) FOOT Door (1) Interior Air Intake (8) Sub Air Mix Door (2) Fresh Air Intake (9) Heater Unit (10) Heater Core (3) Evaporator Core (4) Air Mix Door (11) Evaporator Unit (5) DEF Door (12) Blower Unit...

  • Page 121: Operation And Functions Of Control Panel Switches

    1A–92 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Operation and Functions of Control Panel Switches D The A/C LED remains turned on even if the Auto Switch compressor has been turned off because of the given 1. Pressing this switch turns on the automatic control outside air temperature level.
  • Page 122 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–93 F01RX005 Indication Fan Switch D The Auto LED maintains unaffected. 1. Sets the fan to the specified mode. D Currently selected intake port is indicated. 2. Even when the fan switch is turned off, status display for the Mode, Intake is maintained.

  • Page 123: Overview Of Construction, Movement And Control Of Major Parts Of Automatic Air Conditioner System

    1A–94 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Indication D As long as the MAX control is selected, the immediately preceding indication shall be maintained for the AUTO. D Status display is provided for others. Air Conditioning Switch Pressing this switch turns on or off the A/C (air conditioning) control.
  • Page 124 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–95 Duct Sensor Sun Sensor The duct sensor is the sensor to detect temperature It is a photodiode used for detecting quantity of solar change of the side of evaporator blower coming by fresh radiation.
  • Page 125 1A–96 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Max Hi Relay Actuator This relay turned on or off by the signal from the automatic The actuators are power driven type containing a small heater/air conditioner control unit. As the Max Hi relay is motor.
  • Page 126 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–97 The actuator changes the motor speed using the gear Movement of Mix Actuator and drives each door rotating the output axis united with Position of the air mix door is determined by the controller the sliding contact.

  • Page 127: Overview Of Automatic Control Of Automatic Air Conditioner

    1A–98 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Movement of Mode Actuator Movement of Intake Actuator As target position of the mode door is decided on the The controller on the automatic heater/air conditioner controller of the control unit, the control unit reads the control unit selects an intake mode to be used.
  • Page 128 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–99 Interior Temperature Control Air Flow Control The automatic heater/air conditioner control unit operates In the Auto Mode on the setup temperature signal from the temperature D The automatic heater/air conditioner control unit control switch and other sensor signals to derive the total operates on the setup temperature signal and other signal.
  • Page 129 1A–100 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Mode (Blow Port) Control Intake (Fresh air/interior air switching) Control The automatic heater/air conditioner control unit operates on the setup temperature from the control switch, and In the Full Auto mode, the automatic heater/air temperature and solar radiation quantify from the sensors conditioner control...
  • Page 130 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–101 Compressor Control In the automatic control mode, the automatic heater/air conditioner control unit turns on or off the compressor with the evaporator anti–freeze mechanism using the evaporation sensor. And, when outside air is detected to be low through the outside air temperature sensor signal, the control unit turns off the compressor using the compressor control function.

  • Page 131: Troubleshooting

    1A–102 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Troubleshooting Troubleshooting, Its Overview and When implementing troubleshooting, this self-diagnosis function narrows the range to be searched Procedures at the first step, then check relevant parts one by one according to the “Checking Procedures by Failed The full automatic heater and air conditioner equips with Location”.

  • Page 132: Auto Air Conditioner Control Unit Power Supply Diagnosis

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–103 Auto Air Conditioner Control Unit Power Supply Diagnosis This check is required because a trouble on the auto amplifier (control unit) power supply circuit or grounding circuit prevents accurate troubleshooting. D08RY00138 Condition Possible cause Correction Power source does not supply to —...
  • Page 133 1A–104 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart “A”: Check of Auto Amplifier Power Supply System Step Action Value(s) Is the fuse C–16 normal? Replace the — Go to Step 2 fuse Is the fuse C–20 normal? Replace the — Go to Step 3 fuse Disconnect the auto A/C control unit connector I–32.

  • Page 134: Performance And Movement Checklist For Automatic Air Conditioner Related Parts

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–105 Performance and Movement checklist for Automatic Air Conditioner Related Parts Start the engine, and when the engine coolant reached 122°F check performance and movement of the related parts according the following checklist. Performance Check Using the Manual Switch Checking Approach Item Item...
  • Page 135 1A–106 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Check of Auto Function Checking Approach Item Item Acceptance criteria Acceptance criteria Condition Operation The LED shall come on. Cold air shall be blown out. The following LEDs shall come on: D Blow port mode: Select FC for the D Intake mode temperature.

  • Page 136: Troubleshooting With Self-Diagnosis Function

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–107 Troubleshooting With Self-Diagnosis Function For turning on the self-diagnosis function and switching of Overview of Self-Diagnosis Function the check step, refer to the flow chart given below. You The self-diagnosis is implemented in 3 steps for each can reset the self–diagnosis function by turning the target.
  • Page 137 1A–108 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Displaying the Current Trouble one in 0.5 second interval irrespective of presence or absence of a trouble for a given item. When the display 9 Diagnosing Table items is completed, it is repeated with 3 seconds of Start the engine while holding down both the Auto switch interval in between.
  • Page 138 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–109 As shown above, display of result along nine items is past trouble diagnosis will appear on the indicator lamp repeated with 3-second interval in between. (LED) of the air conditioning switch. Note 1: When checking the sun sensor, apply sufficient Results of the diagnosis along the following five items are light using a 60W bulb.
  • Page 139 1A–110 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Check of Output Equipment F01RY00004...

  • Page 140: Inspection By Failed Location

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–111 Inspection By Failed Location Inspection of the Sensors When the self-diagnosis function has determined that trouble is present on the sensors, check them according to the following flow chart. F01RY00005...
  • Page 141 1A–112 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart 1: In Car Sensor D08RY00174 Step Action Value(s) Disconnect the in car sensor connector. (No.I-34) Is performance of the sensor normal? (Refer to the Replace the later section on “Individual Inspection”) — Go to Step 2 in car sensor Is there continuity between the harness side connector...
  • Page 142 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–113 Chart 2: Ambient Sensor D08RY00140 Step Action Value(s) Disconnect ambient sensor connector. (No.C–86) Replace the Is performance of the ambient sensor normal? (Refer ambient to the later section on “Individual inspection”) — Go to Step 2 sensor Connect the ambient sensor connector.
  • Page 143 1A–114 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart 3: Sun Sensor D08RY00139 Step Action Value(s) Disconnect the sun sensor connector. (No.I–35) Is performance of the sun sensor normal? (Refer to the Replace the later section on individual inspection) — Go to Step 2 sun sensor.

  • Page 144: Inspection Of The Intake Actuator System

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–115 Inspection of the Intake Actuator System D08RY00142...
  • Page 145 1A–116 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition Possible cause Correction Does not work at all — Refer to Chart A Control failure — Refer to Chart B Chart A: Does Not Work At All Step Action Value(s) Is the fuse FL–1 normal? Replace the —...
  • Page 146 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–117 Chart B: Failure on the Intake Control Step Action Value(s) Is the fuse No.C–20 normal? Replace the — Go to Step 2 fuse Is the relay No.B–36 normal? Replace the — Go to Step 3 relay Turn on the ignition switch.

  • Page 147: Inspection Of The Mix Actuator System

    1A–118 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Inspection of the Mix Actuator System D08RY00145 Condition Possible cause Correction Does not work at all — Refer to Chart A Control failure — Refer to Chart B...
  • Page 148 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–119 Chart A: Does Not work At All Step Action Value(s) 1. Turn on the ignition switch (the engine is run). 2. Disconnect the mix actuator connector (I–45). 3. Short-circuit the chassis harness side connector terminal No.I45–3 and No.I45–7.
  • Page 149 1A–120 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart B: Mix Actuator Control Failure Step Action Value(s) Turn the ignition switch (the engine is run). Dose the mix actuator fully stroke when FH and FC of the temperature control lever? — Go to Step 3 Go to Step 2 Repair or replace the air mix door or the link unit.

  • Page 150: Inspection Of The Mode Actuator System

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–121 Inspection of the Mode Actuator System D08RY00146 Condition Possible cause Correction Does not work at all — Refer to Chart A Control failure — Refer to Chart B...
  • Page 151 1A–122 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart A: Does Not Work At All Step Action Value(s) 1. Turn on the ignition switch (the engine is run). 2. Disconnect the mode actuator connector (B–69) 3. Select VENT pressing the mode actuator. Is the battery voltage provided on a regular interval between the harness side connector terminal No.B69–1 (+) and No.B69–5 (-)?
  • Page 152 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–123 Chart B: Mode Actuator Control Failure Step Action Value(s) Turn on the ignition switch (the engine is run). Dose the mode actuator fully stroke when the defrost mode and the vent mode are selected? —...

  • Page 153: Inspection Of The Fan Motor System

    1A–124 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Inspection of the Fan Motor System D08RY00144...
  • Page 154 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–125 Condition Possible cause Correction The fan dose not rotate at all — Refer to Chart A The fan dose not rotate in the — Refer to Chart B MAX–HI mode The fan dose not rotate in any mode —...
  • Page 155 1A–126 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart B: Fan Does Not Rotate in MAX HI Mode Step Action Value(s) Is the MAX-HI relay (I–51) normal? Replace the — Go to Step 2 relay 1. Turn on the ignition switch (the engine is run). 2.
  • Page 156 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–127 Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI Step Action Value(s) Is the power transistor performance normal? (Refer to Replace the the later section on “individual inspection”) power —...
  • Page 157 1A–128 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart D: Fan Does Not Stop Step Action Value(s) 1. Disconnect the max high relay, the power transistor connector I–50 and the auto A/C control unit connector I–33. 2. Turn on the ignition switch. Does the blower motor stop? —...

  • Page 158: Inspection Of The Magnetic Clutch System 1A-129

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–129 Inspection of the Magnetic Clutch System 6VE1 Engine D08RY00143...
  • Page 159 1A–130 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition Possible cause Correction Magnetic clutch does not work — Refer to Chart A Chart A: Magnetic Clutch Does Not work Step Action Value(s) Is the fuse No.C–20 normal? Replace the — Go to Step 2 fuse Is the relay No.X–7 (compressor relay) No.X–5 (A/C Replace the...
  • Page 160 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–131 Chart A: Magnetic Clutch Does Not work (Cont’d) Step Action Value(s) Repair an open circuit between terminal No.X5–1 and I32–14. Is the action complete? — Go to Step 17 — Is there continuity between the harness side connector —...

  • Page 161: Individual Inspection

    1A–132 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Individual Inspection Sun Sensor 1. Disconnect the sun sensor connector (I–35). In Car Sensor 2. Measure the current value on the sun sensor when 1. Disconnect the in car sensor connector (I–34). placed it approximately 15 cm away from 60W 2.
  • Page 162 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–133 Power Transistor In Car Sensor 1. Remove the power transistor connector (I–50) from 1. Turn on the ignition switch (the engine is started). the evaporator assembly. Start the air conditioner in “Full Auto”. 2.
  • Page 163 1A–134 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater (B–36), Thermostat (X–5), And Compressor (X–7) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. D For handling of these relays, refer to Heater Relay in this section. 901RY00041 Triple Pressure Switch (V6, A/T) 1.

  • Page 164: On-Vehicle Service

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–135 On-Vehicle Service Power Transistor Automatic Heater/Air Conditioner Control Unit 874RY00010 Legend 865RY00012 (1) Evaporator Assembly Legend (2) Power Transistor (1) Connector (3) Power Transistor Connector (2) Set Screw (4) Instrument Panel Passenger Lower Cover (3) Instrument Panel Cluster (5) Glove Box (4) Automatic Heater/Air Conditioner Control Unit...

  • Page 165: In Car Sensor

    1A–136 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) In Car Sensor Ambient Sensor 865RY00020 875RY00001 Legend Legend (1) In Car Sensor (1) Ambient Sensor (2) Automatic Heater/Air Conditioner Control Unit (2) Sensor Connector (3) Radiator Grille Removal Removal 1. Disconnect the battery ground cable. 1.

  • Page 166: Sun Sensor

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–137 Sun Sensor Electronic Thermostat 826RY00012 Legend (1) Sun Sensor Removal 1. Disconnect the battery ground cable. 2. Remove the sun sensor. 3. Disconnect the sun sensor connector. 874RX022 Legend Installation (1) Duct Sensor To install, follow the removal step in the reverse order.

  • Page 167: Mode Actuator

    1A–138 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Mode Actuator Mix Actuator 860RY00008 860RY00009 Legend Legend (1) A/T Control Unit (1) Instrument Panel Assembly (2) Actuator Rod (2) Actuator Rod (3) Mode Actuator (3) Mix Actuator (4) Instrument Panel Center Bracket Removal Removal 1.
  • Page 168 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–139 Intake Actuator 873RY00004 Legend (1) Evaporator Assembly (2) Intake Actuator (3) Intake Actuator Connector Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3.

  • Page 169: Power Assisted System

    SECTION POWER ASSISTED SYSTEM 2A–1 TROOPER STEERING POWER ASSISTED SYSTEM CONTENTS Service Precaution ..... . 2A–2 Installation ......2A–38 General Description .

  • Page 170: Service Precaution

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...
  • Page 171 POWER ASSISTED SYSTEM 2A–3 Hydraulic Pump 442RV006 The hydraulic pump is a vane-type design. There are two Pressure Switch openings at the rear of the pump housing. The larger When hydraulic pressure reaches 3650 350 kPa (530 opening contains the cam ring, pressure plate, thrust 50 psi), the pressure switch of the power steering pump plate, rotor and vane assembly, and end plate.
  • Page 172 POWER ASSISTED SYSTEM 2A–4 Steering Linkage 433RS007 Legend (4) Relay Lever (1) Center Track Rod Assembly (5) Rod End,Outer (2) Outer Track Rod Assembly (6) Track Rod (3) Pitman Arm (7) Rod End,Inner The steering linkage consists of a pitman arm, relay lever, center track rod, and two adjustable outer track rods.

  • Page 173: Diagnosis

    POWER ASSISTED SYSTEM 2A–5 Steering Column 3. With the column mounted lock, the ignition and steering operation can be locked to prevent theft of WARNING: TO AVOID DEPLOYMENT WHEN the vehicle. TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT The column can be disassembled and reassembled. USE ELECTRICAL TEST EQUIPMENT, SUCH AS However, to ensure the energy absorbing action, use only BATTERY-POWERED...
  • Page 174 POWER ASSISTED SYSTEM 2A–6 Condition Possible cause Correction Shimmy, Shake or Vibration Tire or wheel out of balance. Balance wheels or replace tire/or wheel. Loose wheel bearings. Replace wheel bearing. Worn steering linkage ball joints. Replace ball joints. Worn upper or lower ball joints. Replace ball joints Excessive wheel runout.
  • Page 175 POWER ASSISTED SYSTEM 2A–7 Condition Possible cause Correction Abnormal Noise Worn, sticky or loose upper or lower Replace. ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Replace. Worn upper or lower control arm Replace. bushing. Loose stabilizer bar.
  • Page 176 POWER ASSISTED SYSTEM 2A–8 Power Steering System There is some noise in all power steering systems. One tween this noise and steering performance. Do not re- of the most common is a hissing sound when the steering place the valve unless the “hissing” noise is extremely ob- wheel is fully turned and the car is not moving.
  • Page 177 POWER ASSISTED SYSTEM 2A–9 Power Steering Pump Foaming milky power steering fluid, low fluid level, and is low. If the fluid level is correct and the pump still foams, possible low pressure can be caused by air in the fluid, or remove the pump from the vehicle and check the housing loss of fluid due to internal pump leakage.
  • Page 178 2A–10 POWER ASSISTED SYSTEM Turn Signal Switch This diagnosis covers mechanical problems only. Refer to Turn Signal Switch in Electrical section for electrical diagnosis. Condition Possible cause Correction Turn Signal Will Not Stay In Turn Foreign material or loose parts Repair or replace signal switch.

  • Page 179: Power Steering System Test

    POWER ASSISTED SYSTEM 2A–11 Power Steering System Test Test Procedure F02RX001 Legend (3) To Power Steering Gear (1) Bolt (M16 1.5) (4) To Power Steering Pump (2) Hose (Vehicle Side) Test of fluid pressure in the power steering system is 4.

  • Page 180: Maintenance

    2A–12 POWER ASSISTED SYSTEM 7. If the pump pressures are within specifications, leave Bleeding The Power Steering System the valve open and turn (or have someone else turn) When a power steering pump or gear has been installed, the steering wheel fully in both directions. Record the or an oil line has been disconnected, the air that has highest pressures and compare with the maximum entered the system must be bled out before the vehicle is...

  • Page 181: Steering Wheel Free Play Adjustment

    POWER ASSISTED SYSTEM 2A–13 4. Install all the lines and hoses. Fill the system with new Adjustment power steering fluid and bleed the system as described in Bleeding The Power Steering System. Operate the engine for about 15 minutes. Remove the pump return line at the pump inlet and plug the connection on the pump.
  • Page 182 2A–14 POWER ASSISTED SYSTEM Camber: Caster(1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the This illustration is viewed from the front of the vehicle. vehicle). A backward tilt is positive(+) and a forward tilt is negative (–).
  • Page 183 POWER ASSISTED SYSTEM 2A–15 6. Inspect the wheels and tires for run-out. Refer to 1. Check and adjust the tire inflation pressures. Wheel Replacement in Wheel and Tire System 2. Park the vehicle on a level ground and move the front section.
  • Page 184 2A–16 POWER ASSISTED SYSTEM Tighten the fulcrum pin bolt to the specified torque. Torque: 152 N·m (112 lb ft) Camber Adjustment The camber angle can be adjusted by means of the camber shims(2) installed in position between the chassis frame(1) and fulcrum pins Camber angle: 0°...
  • Page 185 POWER ASSISTED SYSTEM 2A–17 Toe-in Adjustment 3. Adjust the inside wheel angle of each side with the stop bolts. 1. To adjust the toe-in angle, loosen the lock nuts(2) on NOTE: The maximum protruding length(1) of stop bolt(3) the outer track rods(1) and turn the outer track rods. from the lock nut(2) should be 10 mm or less Turn both rods the same amount, to keep the steering wheel centered .

  • Page 186: Main Data And Specifications

    2A–18 POWER ASSISTED SYSTEM Main Data and Specifications General Specification Caster 2°10’ 45’ Camber 0° 30’ King pin inclination 12°30’ 30’ Toe-in 2 mm (0 0.08 in) Max. steering angle inside 34° (+0° to –2°) outside 32° Torque Specification E03RS001...

  • Page 187: Special Tools

    POWER ASSISTED SYSTEM 2A–19 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–29877–A Tester: Power steering J–39213 Adapter: Power steering tester J–29107 Remover: Pitman arm J–26508 Installer: Extension housing oil seal...

  • Page 188: Power Steering Gear

    2A–20 POWER ASSISTED SYSTEM Power Steering Gear Power Steering Gear and Associated Parts 431RS002 Legend (4) Nut (1) Pipe (5) Gear Box Mounting Bolt and Nut (2) Universal Joint Bolt (6) Gear Box (3) Pitman Arm Removal 1. Remove the stone guard. 2.

  • Page 189: Installation

    POWER ASSISTED SYSTEM 2A–21 7. Make a setting mark(1) across the coupling flange and worm shaft to ensure reassembly of the parts in the original position, then remove universal joint bolt. 431RW004 2. Tighten gear box mounting bolt and nut to specified torque.

  • Page 190: Steering Gear Disassembled View

    2A–22 POWER ASSISTED SYSTEM Steering Gear Disassembled View 440RS001 Legend (7) Seal Ring (1) Dust Cover (8) O-ring (2) Retaining Ring (9) Gear Box (3) Back Up Ring (10) Sector Shaft (4) Oil Seal (11) Top Cover Assembly (5) Ball-nut and Valve Housing Assembly (12) Lock Nut (6) O-ring...

  • Page 191: Disassembly

    POWER ASSISTED SYSTEM 2A–23 Disassembly 6. Remove the top cover bolts and the top cover assembly. CAUTION: Do not clamp the steering gear assembly in a vise by the power cylinder housing. 1. Remove dust cover. 2. Remove retaining ring. 3.

  • Page 192: Inspection And Repair

    2A–24 POWER ASSISTED SYSTEM 8. Remove ball-nut and valve housing assembly. Ball-nut Rotation 440RS005 440RS006 D Always keep the ball nut and valve housing Hold the ball nut and valve housing assembly vertically assembly in a horizontal position to prevent them and see if the ball-nut lowers by turning smoothly.

  • Page 193: Reassembly

    POWER ASSISTED SYSTEM 2A–25 Dust Seal and Seal Ring Setting 3. Apply a thin coat of power steering fluid to the new seal ring(1) and be sure to discard used part, then install seal ring. 4. Apply a thin coat of power steering fluid to the new O-ring and be sure to discard used part, then install o-ring.
  • Page 194 2A–26 POWER ASSISTED SYSTEM D Lock the sector shaft adjusting screw with the lock 6. Install sector shaft. D Tape the sector shaft serrations to protect the seal nut. ring from damage. Lock nut torque: 41 N·m (30 lb ft) D Align the center tooth of ball nut with that of the 10.

  • Page 195: Main Data And Specifications

    POWER ASSISTED SYSTEM 2A–27 Main Data and Specifications General Specifications Steering unit Type Integral, ball screw Gear ratio 16.3 : 1 Torque Specifications E03RS003...

  • Page 196: Power Steering Pump

    2A–28 POWER ASSISTED SYSTEM Power Steering Pump Power Steering Pump and Associated Parts 436RW003 Legend (4) Belt (1) Hose, Suction (5) Pulley (2) Hose, Flexible (6) Pump Assembly (3) Bolt Removal 1. Drain the engine coolant. 2. Place a drain pan below the pump. 3.

  • Page 197: Installation

    POWER ASSISTED SYSTEM 2A–29 4. Remove the drive belt. 5. Remove the pulley from the power steering pump. 6. Disconnect the suction hose. 7. Disconnect the flexible hose. 8. Remove the power steering pump fixing bolt. 9. Remove the pump assembly. CAUTION: When removing the prmp assembly, be careful not to damage the wiring harnessunder the pump housing.

  • Page 198: Power Steering Pump Disassembled View 2A-30

    2A–30 POWER ASSISTED SYSTEM Power Steering Pump Disassembled View 412RX005 Legend (14) Rear Housing Assembly and Pump Cartridge (1) Bolt (15) Side Plate (2) Suction Pipe (16) Rotor and Vane (3) O-ring (17) Pin (4) Front Housing (18) Cam (5) Snap Ring (19) Rear Housing (6) Shaft Assembly (20) Bolt...

  • Page 199: Inspection And Repair

    POWER ASSISTED SYSTEM 2A–31 15. Remove the bolt. Vane 16. Remove the rear housing assembly and the pump cartridge. 17. Remove the gasket. 18. Remove the O-ring. 19. Remove the O-ring. 20. Remove the front housing. 21. Remove the side plate. 22.

  • Page 200: Reassembly

    2A–32 POWER ASSISTED SYSTEM steering fully to the left; engine idle will increase. If system 9. Install a new o-ring and be sure to discard used parts. fails to function properly, disconnect connector at the 10. Install a new gasket and be sure to discard used pressure switch and repeat system check while testing parts.

  • Page 201: Main Data And Specifications

    POWER ASSISTED SYSTEM 2A–33 Main Data and Specifications General Specifications Oil pump Type Vane Operating ATF DEXRON –III fluid Torque Specifications E02RX005...

  • Page 202: Center Track Rod Assembly

    2A–34 POWER ASSISTED SYSTEM Center Track Rod Assembly Center Track Rod Assembly and Associated Parts 433RW001 Legend (3) Nut and Cotter Pin, Relay Lever (1) Nut and Cotter Pin (4) Center Track Rod Assembly (2) Nut and Cotter Pin, Pitman Arm...

  • Page 203: Removal

    POWER ASSISTED SYSTEM 2A–35 Removal 4. Remove nut and cotter pin then use remover J–36831 to remove relay lever from the center track rod. 1. Raise the vehicle and support the frame with suitable CAUTION: Be careful not to damage the ball joint safety stands.

  • Page 204: Outer Track Rod Assembly

    2A–36 POWER ASSISTED SYSTEM Outer Track Rod Assembly Outer Track Rod Assembly and Associated Parts 433RS012 Legend (4) Rod End Assembly, Outer (1) Rod End Assembly, Inner (5) Nut and Cotter Pin, Knuckle Arm (2) Lock Nut, Inner (Left-hand threads) (6) Nut and Cotter Pin, Center Track Rod (3) Lock Nut, Outer...

  • Page 205: Removal

    POWER ASSISTED SYSTEM 2A–37 Removal 5. Apply setting marks (1) to ensure reassembly of the parts in their original position, then remove outer rod 1. Remove wheel and tire assembly. Refer to Wheel end assembly. Replacement in Suspension section. 2. Remove nut and cotter pin, then use remover J–36831 to disconnect outer track rod assembly at the center track rod.
  • Page 206 2A–38 POWER ASSISTED SYSTEM Installation 1. Install inner rod end and align the setting marks applied during disassembly. 2. Tighten the inner lock nut to specified torque. Torque: 118 N·m (87 lb ft) NOTE: For either outer rod, the screw on the right side of the vehicle is threaded counterclockwise.

  • Page 207: Relay Lever

    POWER ASSISTED SYSTEM 2A–39 Relay Lever Relay Lever and Associated Parts 433RS017 Legend (4) Relay Lever (1) Bolt and Nut (5) Nut and Washer (2) Relay Lever and Bracket (6) Nut and Cotter Pin (3) Bracket Removal 1. Raise the vehicle and support the frame with suitable safety stands.

  • Page 208: Installation

    2A–40 POWER ASSISTED SYSTEM 3. Remove stabilizer bar bolt and nut and push the Installation stabilizer bar aside, then remove the relay lever bolts 1. Install bracket. and nuts. 2. Install relay lever. 3. Install nut and washer and tighten the nut to the specified torque.

  • Page 209: Steering Linkage And Associated Parts

    POWER ASSISTED SYSTEM 2A–41 Steering Linkage and Associated Parts Main Data and Specifications Torque Specifications E03RS004...

  • Page 210: Special Tools

    2A–42 POWER ASSISTED SYSTEM Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–36831 Tie rod end remover J–22912–01 Relay lever remover...

  • Page 211: Supplemental Restraint System Steering Wheel & Column

    POWER ASSISTED SYSTEM 2A–43 Supplemental Restraint System Steering Wheel & Column Service Precaution TO AVOID DEPLOYMENT WHEN TROUBLE SHOOT- ING THE SRS SYSTEM, DO NOT USE ELECTRICAL This steering wheel and column repair section covers the TEST EQUIPMENT, SUCH AS BATTERY-POWERED Supplemental Restraint System (SRS) steering column.
  • Page 212 2A–44 POWER ASSISTED SYSTEM Removal Installation To remove the connector, hold the cover insulator(1) and To install the connector, hold the soket insulator(1) and pull it. The cover insulator slides and lock will be released. insert it. The cover insulator slides and connector will be Do not hold the socket insulator(2).

  • Page 213: Inflator Module

    POWER ASSISTED SYSTEM 2A–45 Inflator Module Inflator Module and Associated Parts 827RS048 Legend (2) Inflator Module (1) Module Connector (3) Fixing Bolt Removal 1. Turn the steering wheel so that the vehicle’s wheels are pointing straight ahead. 2. Turn the ignition switch to “LOCK”. 3.

  • Page 214: Inspection And Repair

    2A–46 POWER ASSISTED SYSTEM D Check for defects such as damage and breakage in 6. Disconnect the yellow 2-way SRS connector located behind the inflator module. the lead wire for the igniter. If an abnormality is found as the result of the inspection, replace the inflator module with a new one.

  • Page 215: Steering Wheel

    POWER ASSISTED SYSTEM 2A–47 Steering Wheel Steering Wheel and Associated Parts 827RT022 Legend (3) Inflator Module (1) Horn Lead (4) Steering Wheel (2) Steering Wheel Fixing Nut CAUTION: Once the steering column is removed Removal from the vehicle, the column is extremely 1.
  • Page 216 2A–48 POWER ASSISTED SYSTEM 5. Loosen the inflator module fixing bolt from behind the 9. Apply a setting mark (1) across the steering wheel steering wheel assembly using a TORX driver or and shaft so parts can be reassembled in their original equivalent until the inflator module can be released position, then remove steering wheel.

  • Page 217: Installation

    POWER ASSISTED SYSTEM 2A–49 Installation 7. Turn the ignition switch to “ON” while watching warning light. Light should flash 7 times and then go 1. Install steering wheel by aligning the setting marks off. If lamp does not operate correctly, refer to made when removing.

  • Page 218: Combination Switch

    2A–50 POWER ASSISTED SYSTEM Combination Switch Combination Switch and Associated Parts 431RW001 Legend (4) Combination Switch and SRS Coil Assembly (1) Steering Column Cover (5) Front Console Assembly (2) Steering Wheel (6) Steering Lower Cover (3) Inflator Module (7) Lower Cluster Assembly Removal CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the...
  • Page 219 POWER ASSISTED SYSTEM 2A–51 8. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. Disconnect the yellow 2-way SRS connector located behind the inflator module, then remove inflator module.

  • Page 220: Installation

    2A–52 POWER ASSISTED SYSTEM CAUTION: When turning coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. 430RT009 10. Remove steering column cover. 11. Disconnect the wiring harness connectors located under the steering column, then remove combination switch and SRS coil assembly.
  • Page 221 POWER ASSISTED SYSTEM 2A–53 4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 N·m (25 lb ft) 5. Support the inflator module and carefully connect the module connector. CAUTION: D Never use the air bag assembly from another vehicle.

  • Page 222: Lock Cylinder

    2A–54 POWER ASSISTED SYSTEM Lock Cylinder Lock Cylinder and Associated Parts 431RW003 Legend (6) Cushion Rubber (1) Inflator Module (7) Lock Cylinder Assembly (2) Steering Wheel (8) Front Console Assembly (3) Steering Column Cover (9) Lower Cluster Assembly (4) Combination Switch and SRS Coil Assembly (10) Steering Lower Cover (5) Snap Ring (11) Shift Lock Cable (for A/T)
  • Page 223 POWER ASSISTED SYSTEM 2A–55 8. Loosen the inflator module fixing bolt from behind the 10. Apply a setting mark (1) across the steering wheel steering wheel assembly using a TORX driver or and shaft so parts can be reassembled in their original equivalent until the inflator module can be released position.

  • Page 224: Installation

    2A–56 POWER ASSISTED SYSTEM WARNING: THE INFLATOR MODULE SHOULD 15. Remove snap ring. ALWAYS BE CARRIED WITH THE URETHANE 16. Remove cushion rubber. COVER AWAY FROM YOUR BODY AND SHOULD 17. Remove shift lock cable (for A/T). ALWAYS BE LAID ON A FLAT SURFACE WITH THE 18.

  • Page 225: System Inspection

    POWER ASSISTED SYSTEM 2A–57 7. When installing the steering column cover, be sure to 12. Tighten fixing bolts to specified sequence as route each wire harness as illustrated so that the illustrated. harnesses do not catch on any moving parts. Torque: 8 N·m (69 lb in) 825RW017 827RW003...

  • Page 226: Steering Column

    2A–58 POWER ASSISTED SYSTEM Steering Column Steering Column and Associated Parts 431RW002 Legend (7) Lock Cylinder Assembly (1) Inflator Module (8) Shift Lock Cable (For A/T) (2) Steering Wheel (9) Steering Column Assembly (3) Steering Column Cover (10) Front Console Assembly (4) Combination Switch and SRS Coil Assembly (11) Lower Cluster Assembly (5) Snap Ring...
  • Page 227 POWER ASSISTED SYSTEM 2A–59 CAUTION: The wheel of the vehicle must be straight ahead and the steering column in the “LOCK” position before disconnecting the steering column from the steering gear. Failure to do so will cause the SRS coil assembly to become uncentered which will cause damage to the SRS coil assembly.

  • Page 228: Inspection

    2A–60 POWER ASSISTED SYSTEM 22. Apply a setting mark (1) across the universal joint and steering shaft to reassemble the parts in their original position, then remove steering column assembly. NOTE: A setting mark can be easily made if the shaft is withdrawn a little by loosening the steering shaft universal joint.
  • Page 229 POWER ASSISTED SYSTEM 2A–61 Check clearance between capsule and bracket. It must Sheared Injected Plastic Pin be within 1 mm (0.039 in). Check the sheared injected plastic pins for any loose conditions or damage. 431RW031 Column Tube 431RW033 Check for collapse by measuring the distance as shown in Shaft Length the figure.

  • Page 230: Installation

    2A–62 POWER ASSISTED SYSTEM 431RW035 826RW014 12. When installing the steering column cover, be sure to Tilt Mechanism route each wire harness as illustrated so that the harnesses do not catch any moving parts. Tilt mechanism should moves smoothly. While locked the tilt mechanism, be sure the steering column latch securely by pushing the steering wheel upward and downward.

  • Page 231: System Inspection

    POWER ASSISTED SYSTEM 2A–63 CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for “UX”. D The driver’s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model. When replace the driver’s air bag assembly, confirm the parts number and use only the parts for 1999 model.

  • Page 232: Supplemental Restraint System Steering Wheel & Column And Associated Parts

    2A–64 POWER ASSISTED SYSTEM Supplemental Restraint System Steering Wheel & Column and Associated Parts Main Data and Specifications Torque Specifications E03RW001...

  • Page 233: Special Tools

    POWER ASSISTED SYSTEM 2A–65 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–29752 Steering wheel remover...
  • Page 234 When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 235: General Description

    3C 2 FRONT SUSPENSION General Description C03RW001 Legend (4) Torsion Bar (1) Shock Absorber (5) Link (2) Upper Control Arm (6) Lower Control Arm (3) Height Control Arm (7) Stabilizer Bar The front suspension is designed to allow each wheel to into a height control arm at the crossmember.

  • Page 236: General Diagnosis

    3C 3 FRONT SUSPENSION control arm are attached to the frame by bolts passing which are held to the crossmember by brackets. The ends through the bushings, which are pressed in the frame. of the stabilizer bar are connected to the lower control Side roll of the front suspension is controlled by a spring arms by links.
  • Page 237 3C 4 FRONT SUSPENSION Condition Possible cause Correction Hard Steering Bind in steering linkage ball studs, Replace ball joint. upper or lower ball joint. Improper wheel alignment. Check wheel alignment. Steering gear misadjustment. Check and adjust pinion torque. Tire not adequately inflated. Inflate tires to proper pressure.
  • Page 238 3C 5 FRONT SUSPENSION Condition Possible cause Correction Wandering or Poor Steering Stability Mismatched or unevenly worn tires. Replace tire or inflate tires to proper pressure. Loose steering linkage ball joints. Replace ball joints. Faulty shock absorbers. Replace shock absorber. Loose stabilizer bar.

  • Page 239: Shock Absorber

    3C 6 FRONT SUSPENSION Shock Absorber Shock Absorber and Associated Parts 450RS006 Legend (3) Bolt, Nut and Washer (1) Nut (4) Shock Absorber (2) Rubber Bushing and Washer (5) Rubber Bushing and Washer Removal Installation 1. Raise the vehicle and support it with suitable safety 1.

  • Page 240: Stabilizer Bar

    3C 7 FRONT SUSPENSION Stabilizer Bar Stabilizer Bar and Associated Parts 410RS002 Legend (3) Bracket (1) Nut and Washer (4) Rubber Bushing (2) Link (5) Stabilizer Bar Removal Inspection and Repair Make necessary correction or parts replacement if wear, 1. Raise the vehicle and support the frame with suitable damage, corrosion or any other abnormal conditions are safety stands.

  • Page 241: Torsion Bar

    3C 8 FRONT SUSPENSION Torsion Bar Torsion Bar and Associated Parts 410RS003 Legend (2) Height Control Arm (1) Adjust Bolt, End Piece and Seat (3) Torsion Bar Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2.

  • Page 242: Inspection And Repair

    3C 9 FRONT SUSPENSION D Height control arm 3. Apply the setting marks(2) to the height control arm and torsion bar, then remove height control arm. D Adjust bolt D Rubber seat Installation 1. Apply grease to the serrated portions, then install torsion bar.
  • Page 243 3C 10 FRONT SUSPENSION 2. Apply grease to the portion that fits into the bracket 5. Install adjust bolt and seat, then turn the adjust bolt to then install height control arm and align the setting the setting mark(1) applied during disassembly. marks(2).

  • Page 244: Knuckle

    3C 11 FRONT SUSPENSION Knuckle Knuckle and Associated Parts 410RW001 Legend (6) Needle Bearing (1) Torsion Bar (7) Thrust Washer (2) Lower Ball Joint (8) Oil Seal (3) Back Plate (9) Upper Ball Joint (4) Knuckle Assembly (10) Wheel Speed Sensor (5) Knuckle Removal 4.

  • Page 245: Inspection And Repair

    3C 12 FRONT SUSPENSION 8. Remove wheel speed sensor. 15. Remove needle bearing by using remover J–23907. 9. Remove back plate. 10. Remove lower ball joint by using remover J–29107. CAUTION: Be careful not to damage the ball joint boot. 901RW044 Inspection and Repair Make necessary correction or parts replacement if wear,...

  • Page 246: Front Suspension

    3C 13 FRONT SUSPENSION 2. Apply multipurpose type grease to the thrust washer, and install washer with chamfered side facing knuckle. 3. Use a new oil seal, and apply multipurpose type grease to the area surrounded by the lip (approx. 2 g). Then use installer J–41468 and J–8092 to install oil seal.

  • Page 247: Upper Control Arm

    3C 14 FRONT SUSPENSION Upper Control Arm Upper Control Arm and Associated Parts 450RS007 Legend (7) Bushing (1) Bolt and Plate (8) Plate (2) Camber Shims (9) Nut (3) Caster Shims (10) Speed Sensor Cable (4) Nut Assembly (11) Nut and Cotter Pin (5) Upper Control Arm Assembly (12) Upper Ball Joint (6) Fulcrum Pin...

  • Page 248: Inspection And Repair

    3C 15 FRONT SUSPENSION CAUTION: Be careful not to break the ball joint boot. 901RW048 16. Remove fulcrum pin. 901RW043 7. Remove upper ball joint. Inspection and Repair 8. Remove bolt and plate. 9. Remove nut assembly. Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found 10.

  • Page 249: Installation

    3C 16 FRONT SUSPENSION Installation 1. Install fulcrum pin. 2. Install bushing by using installer J–29755 and J–39376. 450RS012 5. Install upper control arm assembly with the fulcrum pin projections turned inward. 901RW049 450RS013 Legend (1) Projection 901RW050 (2) Outward 3.
  • Page 250 3C 17 FRONT SUSPENSION 7. Install the camber shims(1) between the chassis frame and fulcrum pin. 450RS014 8. Install nut assembly. 9. Install bolt and plate, then tighten the bolt to the specified torque. Torque: 152 N·m (112 lb ft) 10.

  • Page 251: Lower Control Arm

    3C 18 FRONT SUSPENSION Lower Control Arm Lower Control Arm and Associated Parts 450RS015 Legend (8) Bolt, Torsion Bar Arm (1) Nut and Washer, Front (9) Torsion Bar Arm Bracket (2) Bush, Front (10) Torsion Bar (3) Bolt, Front (11) Lower Control Arm (4) Nut and Washer, Rear (12) Lower Ball Joint (5) Bush, Rear...
  • Page 252 3C 19 FRONT SUSPENSION 7. Remove rear nut and washer. 8. Remove torsion bar, refer Torsion Replacement in this section. 9. Remove torsion bar arm bracket. 10. Disconnect the stabilizer link at the lower control arm. 11. Remove the shock absorber lower end from the lower control arm.

  • Page 253: Inspection And Repair

    3C 20 FRONT SUSPENSION 2. Install front bushing by using installer J–36833. 901RW052 901RW036 Inspection and Repair 3. Install lower ball joint bolt. 4. Install torsion bar arm bolt. Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are 5.
  • Page 254 3C 21 FRONT SUSPENSION 13. Install rear nut and washer and tighten lower link nut finger–tight. NOTE: Torque lower control arm nut after adjusting buffer clearance. Buffer clearance: 20 mm (0.79 in) Torque: 196 N·m (145 lb ft) 450RS012 14. Install front nut and washer then tighten lower link nut finger-tight.

  • Page 255: Upper Ball Joint

    3C 22 FRONT SUSPENSION Upper Ball Joint Upper Ball Joint and Associated Parts 450RS022 Legend (2) Upper Ball Joint (1) Bolt, Nut and Washer (3) Nut and Cotter Pin Removal 1. Raise the vehicle and support the frame with suitable safety stands.

  • Page 256: Inspection And Repair

    3C 23 FRONT SUSPENSION D After moving the ball joint 4 or 5 times, attach nut then 3. Remove upper ball joint nut and cotter pin, then use remover J–36831 to remove the upper ball joint from measure the preload. the knuckle.

  • Page 257: Lower Ball Joint

    3C 24 FRONT SUSPENSION Lower Ball Joint Lower Ball Joint and Associated Parts 450RS025 Legend (3) Nut (1) Bolt (4) Nut and Cotter Pin (2) Lower Ball Joint Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2.

  • Page 258: Inspection And Repair

    3C 25 FRONT SUSPENSION 7. Remove nut. Installation 8. Remove lower ball joint. 1. Install bolt. 9. Remove bolt. 2. Install lower ball joint. 3. Install nut and tighten it to the specified torque. Inspection and Repair Torque: 103 N·m (76 lb ft) Make necessary parts replacement if wear, damage, 4.

  • Page 259: Main Data And Specifications

    3C 26 FRONT SUSPENSION Main Data and Specifications General Specifications Front suspension Type Independent wishbone arms, torsion bar spring with stabilizer bar. Torsion bar spring Length 1217 mm (47.9 in) Diameter 26.6 mm (1.05 in) Front shock absorber Type Hydraulic, double acting, telescopic Piston diameter 30.0 mm (1.18 in) Stroke...

  • Page 260: Special Tools

    3C 27 FRONT SUSPENSION Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–36833 J–23907 Remover and Installer Remover; Needle kit; bearing Lower arm front bushing J–36834 J–36838 Remover and Installer Installer; Needle bearing kit; Lower arm rear bushing J–8092 J–36831 Grip...

  • Page 261: Rear Suspension

    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.
  • Page 262 REAR SUSPENSION 3D–2 General Description C03RS003 Legend (3) Shock Absorber (1) Stabilizer Bar (4) Trailing Link (2) Lateral Rod (5) Center Link The rear suspension is a 4-link, coil spring type suspension with a stabilizer bar, consisting of two trailing links, center link, lateral rod, shock absorber, and stabilizer.
  • Page 263 REAR SUSPENSION 3D–3 Coil Spring Coil Spring and Associated Parts 460RS001 Legend (3) Coil Spring (1) Parking Brake Cable Bracket (4) Insulator (2) Shock Absorber (5) Stabilizer Bar Removal 6. Remove spring insulator. 7. Remove the lower insulator and coil spring while 1.
  • Page 264 REAR SUSPENSION 3D–4 Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Coil spring D Insulator Installation 1. Install coil spring and make sure that the coil spring is installed in the proper position.
  • Page 265 REAR SUSPENSION 3D–5 Shock Absorber Shock Absorber and Associated Parts 461RW002 Legend (2) Shock Absorber (1) Bolt and Nut (3) Nut and Washer Removal 2. Install bolt and nut, then tighten the bolt and nut lightly. Retighten to the bolt and nut specified torque after the 1.
  • Page 266 REAR SUSPENSION 3D–6 Trailing Link Trailing Link and Associated Parts 460RW017 Legend (2) Bolt and Nut (1) Parking Brake Cable (3) Trailing Link Removal 1. Remove the parking brake cable from the trailing link. 2. Remove the trailing link fixing bolt and nut. 3.
  • Page 267 REAR SUSPENSION 3D–7 D Install the rubber bushing by using installer J–39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part. 901RW059 Installation 1. Install trailing link. Make sure that the trailing link is in its correct position.
  • Page 268 REAR SUSPENSION 3D–8 Center Link Center Link and Associated Parts 460RX001 Legend (3) Speed Sensor Cable Bracket (1) Center Link (4) Speed Sensor Cable (2) Bolt and Nut Removal 1. Remove the speed sensor cable from the center link. 2. Remove the speed sensor cable bracket from the frame.
  • Page 269 REAR SUSPENSION 3D–9 D Install the rubber bushing by using to installer J–39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part. 901RW059 Installation 1. Install center link. Make sure that the center link is in its correct position.
  • Page 270 REAR SUSPENSION 3D–10 Lateral Rod Lateral Rod and Associated Parts 460RW019 Legend (2) Nut and Washer (1) Bolt and Nut (3) Lateral Rod Removal 1. Remove nut and washer. 2. Remove bolt and nut. 3. Remove lateral rod. Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection.
  • Page 271 REAR SUSPENSION 3D–11 D Install the rubber bushing (Frame side) by using Installer J–39215. NOTE: When mounting rubber bushings, do not use grease on bushings or any other nearby parts. 901RW063 Installation 1. Install lateral rod and make sure that the lateral rod is in its correct position.
  • Page 272 REAR SUSPENSION 3D–12 Stabilizer Bar Stabilizer Bar and Associated Parts 460RW020 Legend (3) Bracket (1) Nut and Washer (4) Rubber Bushing (2) Link (5) Stabilizer Bar Removal 6. Remove rubber bushing. 7. Remove stabilizer bar. 1. Raise the vehicle and support the frame with suitable safety stands.
  • Page 273 REAR SUSPENSION 3D–13 Installation 1. Install stabilizer bar. 2. Install rubber bushing. 3. Install bracket and tighten to the specified torque. Torque: 22 N·m (16 lb ft) 4. Install link. 5. Install nut and washer, then tighten the nut to the specified torque.
  • Page 274 REAR SUSPENSION 3D–14 Main Data and Specifications General Specifications Rear suspension Type 4–Link, coil spring type with stabilizer bar. Coil spring Free length 402mm (15.83in) Spring diameter 12.7mm (0.5in) Coil diameter (inner) 105mm (4.13in) Effective No. of turns 5.32 Total No. of turns 6.82 Shock absorber Type...
  • Page 275 REAR SUSPENSION 3D–15 Torque Specifications E03RW006...
  • Page 276 REAR SUSPENSION 3D–16 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–39214 Remover and Installer; Trailing center link bushing J–39792 Remover and Installer; Lateral rod bushing (axle side) J–39215 Remover and Installer; Lateral rod bushing...

  • Page 277: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    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.

  • Page 278: General Description

    WHEEL AND TIRE SYSTEM 3E–2 General Description 480RS008 Replacement wheels or tires must be equivalent to the metric sized tubeless steel belted radial tires. Correct tire originals in load capacity, specified dimension and pressures and driving habits have an important influence mounting configuration.

  • Page 279: Diagnosis

    WHEEL AND TIRE SYSTEM 3E–3 Diagnosis 480RS001 Irregular and Premature Wear If the following conditions are noted, rotate the tires: D Front tire wear is different from rear. Irregular and/or premature wear has many causes. D Uneven wear exists across the tread of any tire. Some of them are incorrect inflation pressures, lack of tire D Left and right front tire wear is unequal.
  • Page 280 WHEEL AND TIRE SYSTEM 3E–4 Inflation of Tires 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration. Radial Tire Waddle 710RS003 Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile),...
  • Page 281 WHEEL AND TIRE SYSTEM 3E–5 Radial Tire Lead/Pull “Lead/Pull” is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3.
  • Page 282 WHEEL AND TIRE SYSTEM 3E–6 Radial Tire Lead/Pull Correction Chart Step Action 1. Inflate tires to recommended pressure. 2. Road test vehicle on level uncrowned road. Was a problem corrected? Go to Step 2 Switch front tires side to side and road test again. If roughness results,replace Was a problem corrected?
  • Page 283 WHEEL AND TIRE SYSTEM 3E–7 Localized tread wear. Wear in shoulders at points opposed to each other. 480RW004 480RW006 1. Once spotty wear develops in tread due to hard 1. Tire or wheel out of round or distorted. braking or abrupt starting, localized wear tends to be 2.
  • Page 284 WHEEL AND TIRE SYSTEM 3E–8 One sided feather edging. 480RW008 1. Wear caused by repeated hard-cornering. 2. Camber or toe-in incorrect.

  • Page 285: Wheel

    WHEEL AND TIRE SYSTEM 3E–9 Wheel Wheel and Associated Parts 480RW001 Legend (1) Wheel Lug Nut (2) Wheel and Tire Removal 1. Loosen wheel lug nut by approximately 180 g (half a rotation), then raise the vehicle and remove the nuts. 2.

  • Page 286: Tire

    WHEEL AND TIRE SYSTEM 3E–10 Tire Tire Replacement Steel Aluminum When replacement is necessary, the original metric the 1– Vertical play: 1– Vertical play: size should be used. Most metric tire sizes do not have Less than Less than exact corresponding alphanumeric tire sizes. It is 1.5 mm (0.059 in) 0.7 mm (0.028 in)

  • Page 287: Balancing Wheel And Tire

    WHEEL AND TIRE SYSTEM 3E–11 Balancing Wheel and Tire On-vehicle Balancing On-Vehicle balancing methods vary with equipment and tool manufacturers. sure follow each manufacturer’s instructions during balancing operation. Off-vehicle Balancing Most electronic off-vehicle balancers are more accurate than the on-vehicle spin balancers. They are easy to use and give a dynamic balance.

  • Page 288: Main Data And Specifications

    WHEEL AND TIRE SYSTEM 3E–12 Main Data and Specifications General Specifications Wheels Size 16 x 7JJ Offset 38.0 mm (1.50 in) P.C.D., wheel studs 139.7 mm (5.50 in) Standard tire Size P245/70R16 Pressure(Front) 210 kPa (30 psi) Pressure(Rear) 240 kPa (35 psi) Torque Specifications E03RW002...
  • Page 289 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.

  • Page 290: Differential (Front)

    4A1–2 DIFFERENTIAL (FRONT) Front Drive Axle Diagnosis Condition Possible cause Correction Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal. Front axle housing cracked. Repair or replace. Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.

  • Page 291: Pinion Shaft Oil Seal

    DIFFERENTIAL (FRONT) 4A1–3 Pinion Shaft Oil Seal Pinion Shaft Oil Seal and Associated Parts 415RW015 Legend (3) Oil Seal (1) Flange Nut (4) Outer Bearing (2) Flange (5) Collapsible Spacer Removal 1. Raise the vehicle and support it at the frame. The hoist must remain under the front axle housing.

  • Page 292: Inspection And Repair

    4A1–4 DIFFERENTIAL (FRONT) 3. Remove the front propeller shaft. Refer to Front Inspection and Repair Propeller Shaft in this section. Make necessary correction or parts replacement if wear, 4. Remove flange nut by using pinion flange holder damage, corrosion or any other abnormal conditions are J–37221.

  • Page 293: Front Drive Axle Assembly

    DIFFERENTIAL (FRONT) 4A1–5 Front Drive Axle Assembly Front Drive Axle Assembly and Associated Parts 412RW001 Legend (6) Front Axle Case Assembly and Front Drive Shaft Assembly (LH side) (1) Mounting Bolt and Nut (7) Hub Assembly (Disc, Back Plate and Knuckle) (2) Washer and Spacer (8) Front Drive Shaft Assembly (RH side) (3) Breather Hose...
  • Page 294 4A1–6 DIFFERENTIAL (FRONT) 3. Remove the drain bolt to drain differential oil. 14. Disconnect shift switch connector. NOTE: a. During the work, be sure that the diff case is supported by the jack. 412RS031 15. Remove VSV assembly (1). NOTE: Be sure not to remove hose and connector from VSV asm.

  • Page 295: Installation

    DIFFERENTIAL (FRONT) 4A1–7 16. Remove mounting bolt and nut. 19. Lower the vehicle and disconnect the RH front drive shaft assembly, then remove the front axle case assembly and front drive shaft assembly (LH). 412RS004 17. Remove washer and spacer. 18.
  • Page 296 4A1–8 DIFFERENTIAL (FRONT) 5. Tighten the mounting bolt and nut to the specified torque. Torque: 152 N·m (112lb ft) 412RW005 Legend (1) Frame (2) Spacer (3) Washer (4) Bolt (5) Nut 6. Install VSV assembly and tighten nuts to specified torque.

  • Page 297: Differential Assembly

    DIFFERENTIAL (FRONT) 4A1–9 Differential Assembly Disassembled View 415RW001 Legend (12) Bolt (1) Differential Assembly (13) Inner Bearing Outer Race (2) Flange Nut (14) Collapsible Spacer (3) Flange (15) Pinion Gear (4) Dust Cover (16) Inner Bearing (5) Oil Seal (17) Adjust Shim (6) Outer Bearing (18) Diff Cage Assembly (7) Outer Bearing Outer Race...
  • Page 298 4A1–10 DIFFERENTIAL (FRONT) 3. Using holding fixture J–37264 and holding fixture 8. Remove side bearing, using remover J–22888 and base J–3289–20, fix the differential assembly to the adapter J–8107–2. bench. 415RS005 9. Remove adjust shim, note the thickness and position 425RS008 4.
  • Page 299 DIFFERENTIAL (FRONT) 4A1–11 13. Remove the drive pinion assembly using a soft metal 20. Remove the inner bearing outer race (1) and the outer rod and a hammer. bearing outer race (2) by using a brass bar and a hammer. 425RW041 14.

  • Page 300: Reassembly

    4A1–12 DIFFERENTIAL (FRONT) 21. Remove damper and bracket. 2. Using installer J–24252 and grip J–8092, install Inner bearing outer race. 425RW042 415RS008 3. Install adjust shim and adjust drive pinion mounting Reassembly distance 1. Using installer J–24256 and grip J–8092, install outer 1.
  • Page 301 DIFFERENTIAL (FRONT) 4A1–13 3. Clean the side bearing bores. Install the dial Legend indicator with the discs and arbor. Install and (1) Dial Indicator tighten the bearing caps to the specified torque. (2) Ganging Arbor (3) Plunger Torque: 98 N·m (72 lb ft) (4) Gauge Plate 5.
  • Page 302 4A1–14 DIFFERENTIAL (FRONT) 7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indi- cates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness).
  • Page 303 DIFFERENTIAL (FRONT) 4A1–15 8. Select the shim using the chart; Pinion marking –2 –4 –6 –8 –10 Dial indicator reading (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) 2.18 0.081 (0.0858) 2.18 2.20 0.082 (0.0858) (0.0866) 2.18 2.20 2.23...
  • Page 304 4A1–16 DIFFERENTIAL (FRONT) NOTE: Do not apply pressure to the roller cage and apply 2. Tighten the nut to the specified torque using the pressure only to the inner race. pinion flange holder J–37221. Torque: 177–275N·m (130–203 lb ft) NOTE: Discard used flange nut and install new one and do not over tighten the flange nut.
  • Page 305 DIFFERENTIAL (FRONT) 4A1–17 NOTE: When staking, be sure to turn the nut to insure 2. Insert the differential cage assembly with bearing that there is no change in bearing preload. Make sure of outer races into the side bearing bores of the preload again as instructed in 3).
  • Page 306 4A1–18 DIFFERENTIAL (FRONT) 4. Adjust feeler gauge thickness from side to side 13. Install the side bearings together with the selected until ring gear backlash is in the specified range. shims. Backlash: 0.13–0.18 mm(0.005 –0.007 in) 425RS029 Legend 425RS032 (1) Drive Handle:J–8092 With zero end play and correct backlash estab- lished, remove the feeler gauge packs, determine (2) Installer: J–24244...
  • Page 307 DIFFERENTIAL (FRONT) 4A1–19 17. Tighten the cap bolt to the specified torque. Gear Tooth Contact Pattern Check and Adjustment Torque: 98 N·m (72 lb ft) 1. Apply a thin coat of prussian blue or equivalent to the faces of the 7–8 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described in illustration if the contact is...
  • Page 308 4A1–20 DIFFERENTIAL (FRONT) 425RS039 18. Install differential assembly. 3. Fill the axle case with hypoid gear lubricant, to just below the filler hole. 1. Clean the faces of the front axle case and differential carrier. Lubricant capacity: 1.4 liter(1.5 US qt) Apply Three Bond TB1215 or equivalent to the 19.

  • Page 309: Differential Cage Assembly

    DIFFERENTIAL (FRONT) 4A1–21 Differential Cage Assembly Disassembled View 415RS015 Legend (5) Ring Gear (1) Pinion Gear (6) Bolt (2) Thrust Washer (7) Differential Cage (3) Side Gear (8) Lock Pin (4) Cross Pin Disassembly 1. Remove bolt. 2. Remove ring gear. 3.

  • Page 310: Inspection And Repair

    4A1–22 DIFFERENTIAL (FRONT) 4. Remove the cross pin, using a soft metal rod and a 5. Tighten the fixing bolts in a diagonal sequence as hammer. illustrated. 425RS043 415RS016 5. Remove pinion gear. Clearance between the differential pinion 6. Remove side gear. and the cross pin measurement: 7.

  • Page 311: Reassembly

    DIFFERENTIAL (FRONT) 4A1–23 Clearance between the side gear and the Reassembly differential box: 1. Install thrust washer. Standard: 0.03–0.10 mm (0.001–0.004 in) 2. Install side gear. Limit: 0.15 mm(0.006 in) 3. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction.
  • Page 312 4A1–24 DIFFERENTIAL (FRONT) Thickness of thrust washers available: 7. Tighten the bolts in diagonal sequence as illustrated. 1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in, Torque: 108 N·m (80 lb ft) 0.043 in) NOTE: Discard used bolts and install new ones. 425RS050 5.

  • Page 313: Main Data And Specifications

    DIFFERENTIAL (FRONT) 4A1–25 Main Data and Specifications General Specifications Axle tube Type It consists of the duct, a cast iron housing and the axle tube. Gear type Hypoid Gear ratio (to 1) 4.300 Differential type Two pinion Oil capacity liter (US qt) 1.4 (1.5) (Differential) 0.12 (0.13) (Actuator Housing: Shift on the fly) Type of lubricant...
  • Page 314 4A1–26 DIFFERENTIAL (FRONT) E04RW003...

  • Page 315: Special Tools

    DIFFERENTIAL (FRONT) 4A1–27 Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–37221 J–22912–01 Holder; Pinion flange Separator J–24256 J–24250 Installer; Outer bearing Installer; Oil seal outer race J–37264 Differential holding J–8092 fixture Driver handle (Use with J–3289–20 base) J–24252 J–3289–20...
  • Page 316 4A1–28 DIFFERENTIAL (FRONT) TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–24244 J–23597–7 Installer; Side bearing Gauge plate J–39602 J–8001 Remover; Outer bearing Dial indicator J–23597–8 Disc J–23597–1 Arbor J–6133–01 Installer; Pinion bearing J–39209 Punch; End nut lock...
  • Page 317 When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM(SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...
  • Page 318 4A2–2 DIFFERENTIAL (REAR) In case of Work Shop Manual; A-type: Refer to ’98 UBS Work Shop Manual. B-type: Described in ’00UBS Work Shop Manual. 425RY00018...

  • Page 319: General Description

    DIFFERENTIAL (REAR) 4A2–3 General Description The rear axle assembly is of the semi–floating type in driving force at a 90 degree angle from the propeller shaft which the vehicle weight is carried on the axle housing . to the drive shafts. The center line of the pinion gear is below the center line The axle shafts are supported at the wheel end of the of the ring gear (hypoid drive).

  • Page 320: Diagnosis

    4A2–4 DIFFERENTIAL (REAR) Diagnosis Gear Noise Gear noise (whine) is audible from 32 to 89 km/h (20 to 55 Many noises that seem to come from the rear axle mph) under four driving conditions. actually originate from other sources such as tires, road surface, wheel bearings, engine, transmission, muffler, or 1.

  • Page 321: Axle Housing

    DIFFERENTIAL (REAR) 4A2–5 Axle Housing Axle Housing and Associated Parts 420RY00001 Legend (9) Nut (1) Coil Spring and Insulator (10) Differential Assembly (2) Axle Housing Assembly (11) Axle Shaft Assembly (3) ABS Speed Sensor and Harness (12) Brake Disc (4) Nut (13) Brake Pipe (5) Parking Brake Cable (14) Brake Caliper...

  • Page 322: Oil Seal Replacement

    4A2–6 DIFFERENTIAL (REAR) 8. Disconnect the ABS connectors (1) and remove the 19. Remove antilock brake system speed sensor fixing brackets (2) attached to the frame and center link. bolt and the clip and bracket on the axle housing. 20. Remove the brake pipe clip and fixing bolt on the axle housing and take out the brake pipe.

  • Page 323: Axle Shaft

    DIFFERENTIAL (REAR) 4A2–7 13. Install the shock absorber fixing nut to the axle 16. Connect breather hose. housing. 17. Install parking brake cable, Refer to Parking Brakes in 14. Install brake tube flare nut, Refer to Disk Brakes in Brake section. Brake section.

  • Page 324: Inspection And Repair

    4A2–8 DIFFERENTIAL (REAR) 7. Remove parking brake cable mounting 15. Remove the wheel pins using a remover J–6627–A. bolts(Behind the back plate)(1). 420RS007 311RS001 8. Remove the bearing holder mounting nuts. Inspection and Repair 9. Remove axle shaft assembly. Make necessary correction or parts replacement if wear, NOTE: Be sure not to damage the oil seal.

  • Page 325: Oil Seal Replacement

    DIFFERENTIAL (REAR) 4A2–9 Axle Shaft Run–out Oil Seal Replacement Remove the oil seal carefully not to damage the bearing Limit: 1.0 mm (0.039 in) holder bore . When installing, use oil seal installer J–39379. 420RS009 Axle Shaft Flange Run–out 420RS011 Limit: 0.08 mm (0.003 in) Installation 1.

  • Page 326: Pinion Oil Seal

    4A2–10 DIFFERENTIAL (REAR) 6. Install snap ring. 10. Install parking brake assembly, refer to Parking Brakes in Brake section. 7. Install axle shaft assembly. 11. Install antilock brake system sensor. NOTE: Be sure not to damage the oil seal. 12. Install brake disc. 8.

  • Page 327: Inspection And Repair

    DIFFERENTIAL (REAR) 4A2–11 3. Remove flange nut and washer by using pinion flange Inspection and Repair holder J–8614–01 after raising up its staked parts Make necessary correction or parts replacement if wear, completely. damage, corrosion or any other abnormal conditions are found through inspection.

  • Page 328: Differential Assembly

    4A2–12 DIFFERENTIAL (REAR) Differential Assembly Differential Assembly and Associated Parts 425RY00004 Legend (3) Parking Brake Cable (1) Bolt and Nut (4) Differential Assembly (2) Axle Shaft Assembly (5) Nut Removal 6. Remove the parking brake cable fastening clip and disconnect the equalizer section. Refer to Parking 1.

  • Page 329: Installation

    DIFFERENTIAL (REAR) 4A2–13 Installation 2. Install bolt and nut. Tighten the differential carrier mounting bolts and nuts to the specified torque. 1. Clean the contact surfaces of the axle and differential Torque:Nuts 44N·m (33lb ft) carrier. As shown in the drawing, apply Three Bond TB1215 or equivalent then install differential Bolts 66N·m (48lb ft) assembly.

  • Page 330: Disassembled View

    4A2–14 DIFFERENTIAL (REAR) Disassembled View 415RY00002 Legend (10) Inner Bearing Outer Race (1) Flange Nut and Washer (11) Collapsible Spacer (2) Flange (12) Inner Bearing (3) Oil Seal (13) Adjust Shim (Pinion Position) (4) Oil Seal Slinger (14) Drive Pinion Shaft (5) Outer Bearing (15) Adjust Shim (Diff Cage Assembly) (6) Outer Bearing Outer Race...

  • Page 331: Disassembly

    DIFFERENTIAL (REAR) 4A2–15 Disassembly 3. Remove differential cage assembly. 4. Remove side bearing outer race. After removal, keep 1. Using holding fixture J–42832 and holding fixture the right and left hand side bearing assemblies base J–3289–20, fix the differential assembly to the separate maintain inner...
  • Page 332 4A2–16 DIFFERENTIAL (REAR) 8. Removed flange assembly. 16. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a 9. Remove the drive pinion assembly using a soft metal hammer. rod and a hammer.

  • Page 333: Reassembly

    DIFFERENTIAL (REAR) 4A2–17 Reassembly 2. Tighten the nut to the specified torque. Torque: 2.3 N·m (20 lb in) 1. Install outer bearing outer race by using installer J–44461 and grip J–8092. 425RW030 3. Clean the side bearing bores. Place discs and dial 425RY00011 indicator on to arbor, and place tool into position in 2.
  • Page 334 4A2–18 DIFFERENTIAL (REAR) 4. Set the dial indicator J–8001 to “0”. Place it on the 6. After the ZERO setting is obtained, rotate the mounting post of the gauging arbor with the gauging arbor until the dial indicator rod does not contact button touching the indicator pad.
  • Page 335 DIFFERENTIAL (REAR) 4A2–19 8. Select the shim thickness using the chart; Pinion marking Dial –1 –2 –3 –4 –5 –6 –7 –8 –9 –10 indicator reading (inches) 2.12 2.12 0.080 (0.0835) (0.0835) 2.12 2.12 2.14 2.14 2.16 0.081 (0.0835) (0.0835) (0.0843) (0.0843) (0.0850)
  • Page 336 4A2–20 DIFFERENTIAL (REAR) 4. Place the shim (1) on the drive pinion, then install the 10. Install flange nut and washer. inner bearing (2) onto the pinion by using installer 1. Apply lubricant to the pinion threads. J–42828 and a press . 2.
  • Page 337 DIFFERENTIAL (REAR) 4A2–21 4. Using punch J–39209, stake the flange nut at two 2. Insert the differential cage assembly with bearing points. outer races into the side bearing bores of the carrier. NOTE: When staking, be sure to turn the nut to ensure that there is no change in bearing preload.
  • Page 338 4A2–22 DIFFERENTIAL (REAR) 4. Adjust feeler gauge thickness from side to side 12. Install the side bearings together with the selected until ring gear backlash is in the specified range. shims by using installer J–42829 (2) and grip J–8092 (1). Backlash: 0.13–...
  • Page 339 DIFFERENTIAL (REAR) 4A2–23 16. Tighten the bolt to the specified torque. Torque:108N·m (80lb ft) 425RS038 Legend (1) Heel 425RS036 (2) Toe (3) Concave Side(Coast) Gear Tooth Contact Pattern Check and Adjustment (4) Convex Side(Drive) 1. Apply a thin coat of Prussian blue or equivalent to the faces of the 7–8 teeth of the ring gear.

  • Page 340: Differential Cage Assembly

    4A2–24 DIFFERENTIAL (REAR) Differential Cage Assembly Disassembled View 415RY00001 Legend (5) Ring Gear (1) Pinion Mate Gear (6) Bolt (2) Thrust Washer(for Side Gear) (7) Differention Cage (3) Side Gear (8) Lock Pin (4) Differential Shaft...

  • Page 341: Disassembly

    DIFFERENTIAL (REAR) 4A2–25 D Differential cage, carrier Disassembly D Thrust washer 1. Remove bolt. D Oil seal 2. Remove ring gear. Ring gear replacement: 3. Remove lock pin using a small drift. 1. The ring gear should always be replaced with the drive pinion as a set.

  • Page 342: Reassembly

    4A2–26 DIFFERENTIAL (REAR) Clearance between the side gear and the differential Reassembly box. Differential cage Standard: 0.032 – 0.105 mm (0.001 – 0.004 in) Thrust washer Side gear Limit: 0.105 mm (0.004 in) Pinion gear 1. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction.
  • Page 343 DIFFERENTIAL (REAR) 4A2–27 2. Adjust the backlash between the side gear and 5. Install exciter ring (If equipped with rear wheel the pinion gear. antilock). D Press the exciter ring on the differential cage using Backlash: 0.15 – 0.20 mm (0.006 – 0.008 in) the ring gear as a pilot.

  • Page 344: Limited Slip Differential

    4A2–28 DIFFERENTIAL (REAR) Limited Slip Differential Disassembled View 425RY001 Legend (14) Pinion and Pinion shaft (1) Screw (15) Side gear (2) Differential cage A (16) Pressure ring (3) Thrust washer (17) Friction Plate (4) Spring disc (18) Friction disc (5) Friction Plate (19) Friction Plate (6) Friction plate (20) Friction disc...

  • Page 345: Disassembly

    DIFFERENTIAL (REAR) 4A2–29 Disassembly 9. Remove Friction plate. 10. Remove Friction disc. Differential Cages A and B 11. Remove Friction plate. 1. To ensure installation of the parts in original position 12. Remove Friction disc. apply a setting mark before removing the differential cages A and B.
  • Page 346 4A2–30 DIFFERENTIAL (REAR) D Pressure ring D Case 425RY003 425RS059 Legend Legend (3) Sliding surface with the friction disc. When (11) Contact surface with the spring disc. nicks or scratches are found, polish with an oil (12) Inner groove of the differential cage B. stone and repair on a level block using a Repair light nicks and burrs using an oil stone.

  • Page 347: Reassembly

    DIFFERENTIAL (REAR) 4A2–31 Measure the Deformation of the friction disc & plate. Measure the wear of the thrust washer Limit: 0.1 mm (0.004 in) Limit: 1.3 mm (0.05 in) 425RS061 425RS063 Measure the wear of the friction plate & disc Reassembly Limit(A–B): 0.1 mm (0.004 in) Remarks:...
  • Page 348 4A2–32 DIFFERENTIAL (REAR) 2. Measuring the overall length of the pressurering, friction disc and friction plate. D Mount the pinion shaft in the pressurering and then install the friction disc & plate. D Measure the length between the plates over the V–groove.
  • Page 349 DIFFERENTIAL (REAR) 4A2–33 3. After measuring dimensions of each of the above 6. Install Friction plate. sections, proceed with the adjustment in the following 7. Install Friction disc. manner: 8. Install Friction plate. Adjust the clearance to satisfy the equation below. 9.
  • Page 350 4A2–34 DIFFERENTIAL (REAR) 28. Check the operation. D Measure the starting torque using the side gear holder. Starting torque: 29 – 45 N·m (3.0 – 4.6 kg·m/ 22 – 33Ib ft) 425RW065 Legend (1) Side Gear Holder : J–44450...

  • Page 351: Main Data And Specifications

    DIFFERENTIAL (REAR) 4A2–35 Main Data and Specifications General Specifications Rear axle Type Banjo, Semi–floating Rear axle Size 244 mm (9.61 in) Gear type Hypoid Gear ratio (to 1) 4.300 Differential type Two pinion Lubricant Grade GL–5: (Standard differential) GL–5, LSD: (Limited slip differential) Locking Differential Lubricant 80W90 GL–5 (USE Limited Slip Differential Gear Lubricant or Friction...

  • Page 352: Special Tools

    4A2–36 DIFFERENTIAL (REAR) Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–39210 J–37263 Installer; Axle shaft inner Installer; Pinion oil seal seal J–6627–A J–42832 Wheel pin remover Holding fixture J–39211 J–3289–20 Remover; Axle shaft Holding fixture base bearing J–39212 J–42379...
  • Page 353 DIFFERENTIAL (REAR) 4A2–37 TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–8092 J–44451 Grip Gage plate J–44462 J–8001 Installer; Inner bearing Dial indicator outer race J–42824 J–44452 Pilot;Outer Disc (2 required) J–21777–43 J–23597–1 Nut & Stud Arbor J–44453 J–42828 Pilot;Inner Installer;...
  • Page 354 4A2–38 DIFFERENTIAL (REAR) TOOL NO. ILLUSTRATION TOOL NAME J–42829 Installer; Side bearing J–39602 Remover; Outer bearing J–39858 Clutch pack unloading tool kit Includes J–34174–1/J–34174–2 Screw cap and Cap J–22342–15 Forcing screw J–44450 Side gear holder...

  • Page 355: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    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.

  • Page 356: Shift On The Fly System

    4B1–2 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Shift On The Fly System Outline of Shift on The Fly System The shift on the fly system switches between 2 wheel drive (2WD) and 4 wheel drive (4WD) electrically by driver’s pressing the 4WD switch (push button type) on instrument panel.
  • Page 357 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–3 Normal Operation The motor actuator mounted on transfer rear case is of the transfer position switch changes. The vacuum driven by signal from 4WD switch on instrument panel. solenoid valve (VSV) is driven by the signal from transfer After complete the connecting transfer front output gear position switch and the vacuum actuator connects front to, or disconnecting it from, front propeller shaft, condition...
  • Page 358 4B1–4 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Retrial The motor actuator starts transfer gear shifting after gear. This procedure is repeated 3 times in maximum. signal from 4WD switch on instrument panel has been While this procedure, 4WD indicator lamp blinks by 2 Hz. received.
  • Page 359 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–5 Warning at “4L” position :In view of the shifting switch when vehicle is in “4L” condition. In the case this mechanism of transfer, the gear shifting from 4WD to condition continues for 2 seconds, the shifting to 2WD is 2WD at “4L”...

  • Page 360: Functions Of Indicator Lamp

    4B1–6 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Functions of Indicator Lamp Indication of vehicle condition : Indicator lamp is controlled by 4WD control unit and shows vehicle conditions as below. Indicator Vehicle condition 4WD switch Transfer position Front axle switch switch Off (Close) 2WD (Open)

  • Page 361: Diagnosis

    DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–7 Diagnosis When switching from 4WD to 2WD Before Judging That Troubles Occur (Unfaulty mode) 1. In case that the 4WD indicator continues blinking by 2Hz . When Switching from 2WD to 4WD The 4WD indicator continues blinking by 2Hz until 1.
  • Page 362 4B1–8 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Parts Location D08RX005 Legend (8) M–22 (1) I–12 (9) M–23 (2) I–9 (10) M–24 (3) H–7, H–24, H–25 (11) H–10 (4) Fuse Box (12) M–26 (5) C–16 (13) Relay & Fuse Box (6) C–94 (14) H–12, H–16 (7) M–11, M–12...
  • Page 363 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–9 Wiring Diagram D08RW028...
  • Page 364 4B1–10 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) D08RW029...
  • Page 365 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–11 Connector List D04RW030...
  • Page 366 4B1–12 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Diagnosis of The Faults Based on the Status of 4WD Indicator Lamp, 4WD Switch and T/F Change Lever Diagnosis charts are shown on below. If troubles can not be solved after every chart was traced, troubles may occur in the 4WD control unit.
  • Page 367 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–13 3. Case that the indicator keeps blinking by 2Hz after aforementioned Solution 2 is carried out. Step Action Check the air pressure and wear of all tires. Try Solution 2 after adjust the Were problems found? air pressure and replace worn...
  • Page 368 4B1–14 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Fault on switching from 4WD to 2WD 1. Case that indicator does not blink nor turn out. Step Action Short circuit of the indicator Does the indicator turn out by ignition off? Go to Step 2 harness.
  • Page 369 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–15 2. Case that indicator keeps 2Hz blinking after aforementioned Solution 3 is carried out. Step Action Check the air pressure and wear of all tires. Try Solution 3 after adjust the Were problems found? air pressure and replace worn...
  • Page 370 4B1–16 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 3. Case that indicator’s blinking changes to 4Hz after aforementioned Solution 4 is carried out. Step Action Faults on the harness wiring of Can the transfer lever be operated from High to 4L or vice versa? motor actuator.

  • Page 371: Front Axle Diagnosis

    DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–17 Front Axle Diagnosis D When the 4WD switch is operated from 4WD to 2WD, indicator light does not go out. Step Action Drive slow 100 — 200m after a few minutes” idling. Has indicator light gone out? All right.
  • Page 372 4B1–18 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) D When the 4WD switch is operated from 2WD to 4WD, indicator light is not actuated. Step Action Drive slow 100 — 200m after a few minutes” idling. All right. Go to Step 2 Has indicator light actuated? Jack up front tires.

  • Page 373: Shift On The Fly Vacuum Piping And Electric Equipment

    DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–19 Shift On The Fly Vacuum Piping And Electric Equipment Vacuum piping diagram C04RW007 VSV Assembly, Actuator Assembly Vacuum Tank 412RS032 412RS033...

  • Page 374: Inspection And Repair

    4B1–20 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Inspection And Repair Vacuum Piping C04RW008 1. Pull out the Hose A in figure and install a vacuum Check Valve gauge. 2. Plug up Hose B in figure to prevent the leak of vacuum.
  • Page 375 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–21 VSV Assembly 2. With battery connected A – B:There is continuity Inspect the vehicle side harness as follows: C:Closed 3. If 1) and 2) fail, replace with a new VSV. Axle Position Switch 412RS071 Legend (1) Grey...
  • Page 376 4B1–22 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 1. Disassemble the motor actuator from transfer rear Shift rod of the motor actuator moves and stops case. at 2WD position. 412RW037 412RX002 Legend Legend (3) Shift Rod (1) 2WD (4) Connector (2) 4WD (3) Shift Rod 2.

  • Page 377: 4Wd Control Unit

    DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–23 4WD Control Unit 4WD Control Unit Associated Parts 412RW044 Legend (3) Harness Connector (1) Lower Cluster Assembly (4) Nut (2) Front Console Assembly (5) 4WD Control Unit...

  • Page 378: Removal

    4B1–24 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) Removal 1. Remove lower cluster assembly and front console assembly. Refer to Interior Trim in Body and Accessories section. 2. Remove nut. 3. Remove 4WD control unit. 4. Disconnect harness connector (1). 412RW045 Legend (1) Harness Connector...
  • Page 379 WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application. RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out...

  • Page 380: Driveline Control System (Tod)

    4B2–2 DRIVE LINE CONTROL SYSTEM (TOD) General Description C07RY00003 TOD (Torque on Demand) system is traction state control system to vehicle. Transfer Position and Drive Mode Three drive modes can be selected through operation of 4WD switch and transfer lever. Transfer Position 4WD AUTO Mode...
  • Page 381 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–3 the rear wheels is increased against the current torque level in the normal rear wheel drive mode, the control unit detects the slip condition, determines the optimum torque based on the feedback control logic, and increases the torque to the front wheels.

  • Page 382: System Components

    4B2–4 DRIVE LINE CONTROL SYSTEM (TOD) System Components Parts Location A07RY00002 Legend (5) Multi Plate Disk Clutch Pack (1) T/F Connector (6) Electromagnetic Coil (2) 4H Switch and 4L Switch (7) Rear Speed Sensor (3) High-Low Planetary Gear Set (8) Front Speed Sensor (4) Mechanical Lock...
  • Page 383 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–5 Front and Rear Speed Sensors Multi Plate Disk Clutch Pack The sensors are built in the transfer case, and detect the Transmits the torque determined by the clutch pressing rotation of rotors directly coupled to the propeller shafts. force to the front propeller shaft via the front drive chain.
  • Page 384 4B2–6 DRIVE LINE CONTROL SYSTEM (TOD) High-Low Planetary Gear Set Transfer Connector Establishes an auxiliary transmission mechanism. When Transmits the input and output signals of the speed the transfer shift lever is set to the 2H or TOD position, the sensors, electromagnetic coil, and 4H and 4L switche to reduction gear ratio is 1.000 and the corresponding the vehicle harness.
  • Page 385 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–7 Check Lamp Inform the following items. D Bulb check D Fail (fail alarm) D Trouble code 821RW078 TOD ECU This control unit is mounted to the front right hand seat via a special bracket. F07RW029...

  • Page 386: Functions Of Indicator Lamp

    4B2–8 DRIVE LINE CONTROL SYSTEM (TOD) Functions of Indicator Lamp TOD Indicator Lamps C07RY00017 Indication of Drive Mode NOTE: After the transfer lever is set to the specified position and the AXLE switch generates compliant The transfer lever position signals are transmitted to the signals, the normal output status is returned.
  • Page 387 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–9 C07RW015 Bulb Check When the starter switch is turned on, the TOD indicator lamps go on as shown below. NOTE: Once the starter switch is turned on, all the TOD indicator lamps are lit for two seconds even if the transfer lever is in any position.
  • Page 388 4B2–10 DRIVE LINE CONTROL SYSTEM (TOD) Simplified checking method of ABS IN and BRAKE ON signals: In the event that any of the signal inputs listed below are observed while the self-diagnostic code is being displayed (the self-diagnostic connector is short-circuited to GND), you can simply check the ABS IN and BRAKE ON signals as shown in the figures below.

  • Page 389: Diagnosis

    DRIVE LINE CONTROL SYSTEM (TOD) 4B2–11 Diagnosis General Information Diagnosis The troubles on TOD are classified into the group that can be identified by the lighting status of the TOD indicator lamps and those that can be recognized as abnormal phenomena of the vehicle by the driver.
  • Page 390 4B2–12 DRIVE LINE CONTROL SYSTEM (TOD) D If no trouble codes exist, code “12” is displayed Indication Method of Trouble Code continuously. D Short-circuit terminal 8 of the self-diagnostic D If trouble codes exist, code “12” is displayed three connector to GND to display the trouble code on the times, and the trouble codes, starting from the smaller CHECK lamp.
  • Page 391 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–13 How to Clear The Trouble Code Trouble Intermittently Observed The trouble codes saved to the control unit can be deleted Troubles intermittently observed are mostly attributable by the following procedure if the starter switch is being in to temporary imperfect connection of harnesses and the OFF position.
  • Page 392 4B2–14 DRIVE LINE CONTROL SYSTEM (TOD) 7. Slowly start the vehicle in the 4L mode, and accelerate to at least 20 km/h. Apply the brake to completely stop the vehicle. If the CHECK lamp starts blinking during the test run, read the trouble codes and give appropriate maintenance according to the diagnostic procedure.

  • Page 393: Basic Diagnostic Flow Chart

    DRIVE LINE CONTROL SYSTEM (TOD) 4B2–15 Basic Diagnostic Flow Chart C07RW023–1...

  • Page 394: Parts Location

    4B2–16 DRIVE LINE CONTROL SYSTEM (TOD) Parts Location D08RW367 Legend (11) M–24 (1) I–9 (12) H–10 (2) C–63 (13) H–17 (3) H–7, H–8, H–25 (14) E–54 (4) H–33 (15) E–29 (5) Fuse Box (16) Relay & Fuse Box (6) C–16 (17) H–12 (7) B–13 (18) B–48, B–49...

  • Page 395: Circuit Diagram

    DRIVE LINE CONTROL SYSTEM (TOD) 4B2–17 Circuit Diagram D04RY00003...
  • Page 396 4B2–18 DRIVE LINE CONTROL SYSTEM (TOD) D04RY00002...
  • Page 397 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–19 D04RY00010...

  • Page 398: Connector List

    4B2–20 DRIVE LINE CONTROL SYSTEM (TOD) Connector List Connector face Connector face B-13 B-48 H-10 B-49 H-12 C-16 H-17 C-63 H-25 C-94 H-33 E-29 H-36 E-54 H-55 H-57...
  • Page 399 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–21 Connector face I-12 M-22 M-23 M-24 M-27...

  • Page 400: Checking Failed Pin

    4B2–22 DRIVE LINE CONTROL SYSTEM (TOD) Checking Failed Pin Connector Pin Assignment D ECU pin assignment D04RY00011 NAME CONTENTS Not used Not used Not used D–G MAP Gas/Diesel Not used IND. b Display Front–B Not used IND. Rr Display Rear–E Not used Not used SOL (+)
  • Page 401 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–23 NAME CONTENTS Not used Not used Not used DIAG Diagnostic Input TOD SW TOD Switch 4H SW 4H Switch Input Frt. Sig Front Speed Signal ABS IN ABS In Ignition Not used 4WD OUT 4WD Signal Output BRAKE Brake Switch Input...
  • Page 402 4B2–24 DRIVE LINE CONTROL SYSTEM (TOD) Reference D Transfer connector pin assignment (connector on the transfer case) for inspection of transfer pins. 810RW310 NAME CONTENTS Ref. (Rer. ) Rear speed sensor reference output Ref. (Frt. ) Front speed sensor reference output SW GND SW GND 4H SW (+)

  • Page 403: Checking Failed Tod Control Unit Pin

    DRIVE LINE CONTROL SYSTEM (TOD) 4B2–25 Checking Failed TOD Control Unit Pin NOTE: 2. Before removing the ECU, turn off the ignition switch. 3. If the standard values are not observed, check the 1. Unplug the ECU connector and the pins, unless pins with other testers.

  • Page 404: Tech 2 Scan Tool

    4B2–26 DRIVE LINE CONTROL SYSTEM (TOD) Tech 2 Scan Tool From 98 MY, Isuzu dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide. 901RW257 Legend (3) DLC Cable (1) PCMCIA Card...
  • Page 405 Isuzu systems PCMCIA card. Follow the Tech 2, the following steps must be performed: operating procedure below. 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (4).
  • Page 406 4B2–28 DRIVE LINE CONTROL SYSTEM (TOD) 060RX062...

  • Page 407: Diagnostic Trouble Codes

    DRIVE LINE CONTROL SYSTEM (TOD) 4B2–29 Diagnostic Trouble Codes Code Item Diagnosis Check flow No. Start code Normal — Shorted GND Front speed sensor Input abnormality (open, sig or com) Shorted V Front speed sensor Input abnormality Shorted or disconnected wiring, abnormality in input CPU abnormality Rear speed sensor...

  • Page 408: Diagnosis From Trouble Codes

    4B2–30 DRIVE LINE CONTROL SYSTEM (TOD) Diagnosis from Trouble Codes D Diagnose the based on the fault that have been saved to the control unit according to the system self-diagnostic function. Check flow Trouble code Phenomenon Standard 23, 36, 37, 38 The ECU is failed.
  • Page 409 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–31 Check flow Trouble code Phenomenon Standard Front speed sensor signal open or 0.3 < sensor voltage GND short, speed sensor com open. NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken. D04RY00004...
  • Page 410 4B2–32 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Start the engine. 2. Select 4H (TOD) mode. Is the memory except DTC 14? Go to Step 3 Go to Step 2 Is the continuity between harness of terminal 32 and ground Replace speed (vehicle side terminal of the front speed sensor)? sensor.
  • Page 411 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–33 Check flow Trouble code Phenomenon Standard Hi level : 4.5 ∼ 6.0 V The front speed sensor no pulse. Lo level : 0.7 ∼ 2.0 V Frequency (F) = 766 Hz (at 30 mile/h) NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.
  • Page 412 4B2–34 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Connect TECH 2. Repair and inspection front While running in TOD mode, does TECH–2’s front speed sensor speed sensor indication change with vehicle speed? tone wheel. Go to Step 2 Go to Step 4 Is the continuity between harness of terminal 32 and ground Replace speed (vehicle side terminal of the front speed sensor)?
  • Page 413 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–35 Check flow Trouble code Phenomenon Standard Hi level : 4.5 ∼ 6.0 V The front speed sensor no pulse. Lo level : 0.7 ∼ 2.0 V Frequency (F) = 766 Hz (at 30 mile/h) NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.
  • Page 414 4B2–36 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Connect TECH 2. Repair and inspection front While running in TOD mode, does TECH–2’s front speed sensor speed sensor indication change with vehicle speed? tone wheel. Go to Step 2 Go to Step 4 Is the continuity between harness of terminal 45 and ground Replace speed (vehicle side terminal of the rear speed sensor)?
  • Page 415 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–37 Check flow Trouble code Phenomenon Standard Rear speed sensor signal open or 0.3 V < sensor voltage GND short, speed sensor COM open. NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken. D04RY00004...
  • Page 416 4B2–38 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Start the engine. 2. Select 4H (TOD) mode. Is the memory except DTC 24? Go to Step 3 Go to Step 2 Is the continuity between harness of terminal 45 and ground Replace speed (vehicle side terminal of the rear speed sensor)? sensor.
  • Page 417 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–39 Check flow Trouble code Phenomenon Standard Reference ] 5 V The reference is short-circuited to GND. The reference Vb is short-circuited. If the reference wire (15) is short-circuited to GND, the speed signal is not generated. If the wire is short-circuited to the battery voltage, the signal level becomes faulty.
  • Page 418 4B2–40 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Start the engine. Does the voltage between terminals 12 and 13 meet the standard Go to Step 8 Go to Step 2 Is the voltage below the standard? Go to Step 3 Go to Step 7 1.
  • Page 419 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–41 Check flow Trouble code Phenomenon Standard The voltage of the throttle position See below table. sensor (TPS) is faulty. NOTE: The signal voltage from the TPS deviates from the standard range. D04RY00004...
  • Page 420 4B2–42 DRIVE LINE CONTROL SYSTEM (TOD) D04RY00012...
  • Page 421 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–43 Step Action 1. Turn off the starter switch. Charge or replace the Is the battery voltage normal? battery. Go to Step 2 Go to Step 6 1. Turn on the starter switch. Does the voltage between terminals 15 and 46 fall within the standard range above? Go to Step 6 Go to Step 3...
  • Page 422 4B2–44 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The electromagnetic coil is broken. — D04RY00008...
  • Page 423 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–45 Step Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the continuity established between terminals (B–49)11 and (B–49)22? Go to Step 2 Go to Step 4 1. Connect the ECU connector. 2.
  • Page 424 4B2–46 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The electromagnetic coil GND is Resistance: 1.0 to 5.0 ohm (at ordi- short-circuited. nary temperature) D04RY00008...
  • Page 425 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–47 Step Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Does the resistance between terminals (B–49)11 and (B–49)22 indicate 1.0 to 5.0 ohm? Go to Step 2 Go to Step 3 1.
  • Page 426 4B2–48 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The shift on the fly system (front — hub) works incorrectly. NOTE: The shift on the fly system is not changed between 2WD and 4WD modes normally. CAUTION: If code 32 or 33 is also observed, remove the trouble associated with code 32 or 33 first.
  • Page 427 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–49 Step Action 1. Turn on the starter switch. 2. Set the transfer to the 2H mode. Is the battery voltage observed between terminals 23 and 46? Go to Step 2 Go to Step 5 Is the battery voltage observed between terminals 42 and 46? Go to Step 3 Go to Step 6...
  • Page 428 4B2–50 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The on/off signal (ADC) line of the — shift on the fly system (front hub) is broken, or the line is short-circuited to the battery. NOTE: The on/off signal line of the shift on the fly system is broken, or the line is short–circuited to the battery.
  • Page 429 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–51 Step Action 1. Turn off the starter switch. The harness is 2. Disconnect the ECU connector from ECU. broken. Repair the circuit. Is the continuity established between terminals (B–48)1 and (B–48)24? Go to Step 2 Go to Step 3 Does the voltage between terminals (B–48)1 and (B–48)24 The battery is...
  • Page 430 4B2–52 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The ADC line is short-circuited to — GND. NOTE: D The on/off signal line of the shift on the fly system is short–circuited to GND. D The system enters into the fail-safe mode because of fusing or system protection.
  • Page 431 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–53 Step Action 1. Turn off the starter switch. The phenomenon 2. Disconnect the ECU connector from ECU. is not reproduced. Does the resistance between terminals (B–48)1 and (B–48)24 Refer to meet the standard, R = 21 4 ohms? “Troubles intermittently...

  • Page 432: Trouble Diagnosis Depending On The Status Of Tod Indicator

    4B2–54 DRIVE LINE CONTROL SYSTEM (TOD) Trouble Diagnosis Depending on The Status of TOD Indicator Functional check with TOD indicator light is conducted prior to check on Charts A–H. D After the starter is switched on, check and see if the status has become as tabulated below.
  • Page 433 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–55 Chart A Indicator drive circuit Function of circuit The circuit informs the indicator of the working condition of the ECU. Fail condition All the TOD indicator lamps and CHECK lamp are lit, and go off momentarily at an inter- val of about two seconds.
  • Page 434 4B2–56 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Turn on the starter switch. The ECU has failed. Replace Check the battery Is the battery voltage observed between terminals 14 and 46 or 34 circuit. the ECU. and 46? Go to Step 2 Go to Step 2 Check that all the parts are mounted.
  • Page 435 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–57 Chart B–1 The 4WD switch circuit wires are broken or short-circuited to the GND Function of circuit — Fail condition Even after the transfer position is select from TOD to 2H, the indicator lamp status is not changed.
  • Page 436 4B2–58 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Turn on the starter switch. Repair the 4WD Auto Switch When the 4WD Auto Switch is select to the 4WD position, is 0 V circuit. observed between terminal 30 and 46? Go to Step 2 Go to Step 4 When the 4WD Auto Switch is select to the 2WD position, is 12 V...
  • Page 437 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–59 Chart B–2 The 4WD AUTO SWITCH circuit is short to battery. Function of circuit — Fail condition Even after the transfer mode is select from 2H to TOD. Indicator lamp status Transfer position D04RY00015...
  • Page 438 4B2–60 DRIVE LINE CONTROL SYSTEM (TOD) Step Action When the 4WD Auto Switch is select to the 4WD position, is 0 V Repair the 4WD observed between terminal 30 and 46 (4H switch)? Auto Switch circuit. Go to Step 2 Go to Step 7 When the 4WD Auto Switch is select to the 2WD position, is 12 V Repair the 4WD...
  • Page 439 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–61 Chart C–1 4H switch circuit wires are broken or the battery is short-circuited. Function of circuit — Fail condition When the 4WD Auto Switch is 4WD mode. When the lever is shifted from 4L to TOD, the 4L mode remains on the indicator and the TOD mode is displayed without turning off the previous mode.
  • Page 440 4B2–62 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Turn on the starter switch. When the transfer lever is shifted to the high position, is 5V observed between terminals 31 and 46 (4H switch)? Go to Step 2 Go to Step 4 When the transfer lever is shifted to the 4L position, is 5V Go to Step 3 Go to Step 4...
  • Page 441 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–63 Step Action Is the continuity established between transfer terminals (M–27)4 The harness is and body? broken between The ECU has terminal (M-27)4 and GND. Repair failed. Replace the ECU. the circuit. Go to Step 14 Go to Step 14 Check that all the parts are mounted.
  • Page 442 4B2–64 DRIVE LINE CONTROL SYSTEM (TOD) Chart C–2 The 4H switch circuit is short-circuited to GND. Function of circuit — Fail condition When the transfer lever is shifted to 4L, the indicator lamp status is not changed. Indicator lamp status Transfer position D04RY00015...
  • Page 443 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–65 Step Action When the transfer lever is shifted to the High position, is 5V observed between terminals 31 and 46 (4H switch)? Go to Step 2 Go to Step 14 When the transfer lever is shifted to the neutral position, is 0V observed between terminals 31 and 46 (4H switch)? Go to Step 3 Go to Step 14...
  • Page 444 4B2–66 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Turn off the starter switch. 2. Disconnect the ECU connector. When the transfer lever is shifted to the neutral position, is the continuity established between terminals (B–48)9 and (B–48)24 Go to Step 15 Go to Step 17 (4H switch)? When the transfer lever is shifted to the high position, is the...
  • Page 445 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–67 Chart D–1 4L switch circuit wires are broken or the battery is short-circuited. Function of circuit — Fail condition The TOD mode is displayed in the neutral position between high and 4L. When the lever is shifted to the 4L position, the TOD mode is displayed.
  • Page 446 4B2–68 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Turn on the starter switch. When the transfer lever is shifted to the high position, is 5V observed between terminals 44 and 46 (4L switch)? Go to Step 2 Go to Step 4 When the transfer lever is shifted to the neutral position, is 0V Go to Step 3 Go to Step 4...
  • Page 447 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–69 Step Action When the transfer lever is shifted to the high position, is the Repair the continuity established between transfer connector terminals transfer (M-27)12 and GND? assembly. Go to Step 13 Go to Step 13 Check that all the parts are mounted.
  • Page 448 4B2–70 DRIVE LINE CONTROL SYSTEM (TOD) Chart D–2 The 4L switch circuit is short-circuited to GND. Function of circuit — Fail condition The 4L mode is displayed even in the 2H or TOD. Indicator lamp status Transfer position 2H or TOD D04RY00006...
  • Page 449 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–71 Step Action When the transfer lever is shifted to the high position, is 5V observed between terminals 44 and 46 (4L switch)? Go to Step 2 Go to Step 7 When the transfer lever is shifted to the neutral position, is 0V observed between terminals 44 and 46 (4L switch)? Go to Step 3 Go to Step 7...
  • Page 450 4B2–72 DRIVE LINE CONTROL SYSTEM (TOD) Step Action When the transfer lever is shifted to the 4L position, is the Repair the continuity established between terminals (M-27)12 and GND? transfer assembly. Go to Step 15 Go to Step 16 When the transfer lever is shifted to the high position, is the GND is continuity established between terminals (M-27)12 and GND? short-circuited...
  • Page 451 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–73 Chart E–1 AXLE switch circuit wires are broken. Function of circuit — Fail condition Both the TOD and 4L modes are disabled. (The transition status is not removed.) Indicator lamp status Transfer position D04RY00007...
  • Page 452 4B2–74 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Start the engine. When the transfer lever is shifted to the neutral position between high and 4L, is the battery voltage observed between terminals 42 and 46? Go to Step 2 Go to Step 7 When the transfer lever is shifted to the high position and 4WD Auto switch selected to 4WD position, is 0V observed between terminals 42 and 46?
  • Page 453 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–75 Step Action When the transfer lever is shifted to the high position and 4WD Repair the circuit Auto Switch selected to 4WD position, is 0V observed on each of replace the VSV? VSV. Go to Step 16 Go to Step 19 When the transfer lever is shifted to the 4L position, is 0V Repair the circuit...
  • Page 454 4B2–76 DRIVE LINE CONTROL SYSTEM (TOD) Chart E–2 The AXLE switch circuit is short-circuited to GND. Function of circuit — Fail condition Even after the 4WD Auto Switch is select to the 2WD position, the 2WD mode is not en- abled.
  • Page 455 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–77 Step Action Start the engine. When the transfer lever is shifted to the neutral position between high and 4L, is the battery voltage observed between terminals 42 and 46? Go to Step 2 Go to Step 7 When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed between terminals 42 and 46?
  • Page 456 4B2–78 DRIVE LINE CONTROL SYSTEM (TOD) Step Action When the transfer lever is shifted to the 4L position, is 0V Repair the circuit observed on each VSV? of replace the VSV. Go to Step 17 Go to Step 19 Is the vacuum pressure supplied to the VSV? Repair the vacuum system.
  • Page 457 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–79 Chart G The trouble codes are displayed. Function of circuit — Fail condition Indicator lamp status Transfer position — D04RY00009...
  • Page 458 4B2–80 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Disconnect the ECU connector from ECU. The ECU has failed. Replace Is the continuity established between terminals (B–48)7 and the ECU. (B–48)24? Go to Step 2 Go to Step 3 Is the self-diagnostic connector short-circuited? Open the self-diagnostic connector.
  • Page 459 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–81 Chart H lighting switch circuit Function of circuit Reads in the status of lighting switch, reducing the indicator at night. Fail condition Even if the lighting switch is pressed on and off, brightness does not change. Indicator lamp status Transfer position All position (exsample TOD mode)
  • Page 460 4B2–82 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Disconnect ECU terminal. Wires are broken 2. Turn on the starter switch. lighting SW circuit. Repair Is battery voltage observed between ECU terminals (B–48)18 the circuit. and (B–48)24? Go to Step 2 Go to Step 4 Turn lighting SW “ON”.

  • Page 461: Diagnosis From Symptom

    DRIVE LINE CONTROL SYSTEM (TOD) 4B2–83 Diagnosis from Symptom Troubles that are not indicated by the warning lamp are listed in the table below. These troubles are caused by the faults that cannot be detected by the self-diagnostic function of the control unit. If this type of trouble is observed, interview the customer and conduct test runs to reproduce the trouble, cross-check the reported trouble with the listed...
  • Page 462 4B2–84 DRIVE LINE CONTROL SYSTEM (TOD) Chart 1 The tight corner braking is observed. Function of circuit — Fail condition When the vehicle is subject to full steering in the TOD mode, the drive resistance gets large or the judder occurs. Otherwise, the above phenomenon is observed only when the brake is applied.
  • Page 463 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–85 Step Action Are the front and rear tires in specified size? Replace the tires with specified ones, and service the new tires. Go to Step 2 Go to Step 16 Is the tire pressure correct? Replace the tires with specified ones, and service...
  • Page 464 4B2–86 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Apply the brake and fully turn the steering to the left (or right) Repair the The ECU has end, and start the creep run. transfer failed. Replace assembly. the ECU. Does the voltage between terminals (B–49)11 and (B–49)22 range between 0.1 and 1.0V? Go to Step 16 Go to Step 16...
  • Page 465 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–87 Chart 2 The 4WD mode is not active. Function of circuit — Fail condition The rear wheels spin in the TOD mode, so the driving torque is not transmitted to the front wheels. The indicator lamps will not show the 4L and TOD status. D04RY00009...
  • Page 466 4B2–88 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Is the trouble code 31 or 26 recorded? Examine the trouble based on “Diagnosis from Trouble Codes”. Go to Step 7 Go to Step 2 Is any of the trouble codes 28, 32 and 33 recorded? Examine the trouble based on “Diagnosis from...
  • Page 467 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–89 Chart 3 The shift on the fly system generates gear noises. (The fuel economy is bad in the 2H mode.) Function of circuit — Fail condition When the vehicle is run in the 2H mode, the shift on the fly system generates gear noises or the front wheel gears are engaged to generate a shock.
  • Page 468 4B2–90 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Do the indicator lamps show the correct status? Examine the trouble based on “Diagnosis from Trouble Codes”. Go to Step 2 Go to Step 2 Is any of the trouble codes 28, 32 and 33 recorded? Examine the trouble based on “Diagnosis from...
  • Page 469 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–91 Chart 4 The braking distance gets long even when the ABS is active. Function of circuit — Fail condition Enough deceleration is not obtained and the braking distance gets long even when the ABS is active in the 2H mode. D04RY00009...
  • Page 470 4B2–92 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Are the brake and ABS systems healthy? Repair the brake and ABS. Go to Step 2 Go to Step 4 Turn on the starter switch. Repair the Is the battery voltage observed between terminals 14 and 22? battery system.

  • Page 471: Drive Shaft System

    SECTION DRIVE SHAFT SYSTEM 4C–1 TROOPER DRIVELINE/AXLE DRIVE SHAFT SYSTEM CONTENTS Service Precaution ..... . 4C–2 Shift On The Fly System and Associated Parts .

  • Page 472: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    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.

  • Page 473: Diagnosis

    DRIVE SHAFT SYSTEM 4C–3 Diagnosis Condition Possible cause Correction Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal. Front axle housing cracked. Repair or replace. Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level. Oil seal worn or defective.

  • Page 474: Front Hub And Disc (2Wd Model)

    4C–4 DRIVE SHAFT SYSTEM Front Hub and Disc (2WD Model) Disassembled View 411RY00003 Legend (7) Hub and Disc Assembly (1) Bolt (8) ABS Sensor Ring (2) Cover and Gasket (9) Inner Bearing (3) Packing (10) Oil Seal (4) Lock Washer (11) Bolt (5) Hub Nut (12) Wheel Pin...
  • Page 475 DRIVE SHAFT SYSTEM 4C–5 3. Remove cover bolt. 11. Remove bolt. 4. Remove cover and gasket. 12. If necessary, replace the wheel pin in the following manner. 5. Remove lock washer. D Scribe mark(1) on hub to disc before disassembly 6.

  • Page 476: Inspection And Repair

    4C–6 DRIVE SHAFT SYSTEM D Place hub on a suitable work surface and remove NOTE: Be sure wheel stud is started squarely and seats wheel studs, as required, using a hammer. completely. 411RS004 411RS005 2. Align index marks(1) and install hub to disc. Inspection and Repair Check the following parts for wear, damage or other abnormal conditions.
  • Page 477 DRIVE SHAFT SYSTEM 4C–7 3. Install bolt. 5. Install inner bearing. Tighten the bolts to the specified torque. Install the outer race by driving it into the hub by using installer J–36829 and grip J–8092. Torque: 103 N·m (76 lb ft) 411RS023 411RS021 6.
  • Page 478 4C–8 DRIVE SHAFT SYSTEM 7. Apply Multipurpose grease NLGI No.2 in the hub and bearing. 35 g (1.23 oz) Outer bearing 10 g (0.35 oz) Inner bearing 15 g (0.53 oz) 8. Install hub nut by using wrench J–36827. Turn the place where there is a chamfer in the tapped hole to the outer side, and attach the nut.

  • Page 479: Main Data And Specifications

    DRIVE SHAFT SYSTEM 4C–9 Main Data and Specifications Torque Specifications E04RW00001...

  • Page 480: Special Tools

    4C–10 DRIVE SHAFT SYSTEM Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–36827 Wrench; Hub nut J–36829 Installer; Inner bearing J–36828 Installer; Outer bearing J–36830 Installer; Oil seal...

  • Page 481: Front Hub And Disc (4Wd Model)

    DRIVE SHAFT SYSTEM 4C–11 Front Hub and Disc (4WD Model) Disassembled View 411RW001 Legend (7) Outer Bearing (1) Bolt (8) Bolt (2) Cap (9) Hub and Disc Assembly (3) Snap Ring and Shim (10) Wheel Pin (4) Hub Flange (11) ABS Sensor Ring (5) Lock Washer and Lock Screw (12) Inner Bearing (6) Hub Nut...

  • Page 482: Inspection And Repair

    4C–12 DRIVE SHAFT SYSTEM D Place hub on a suitable work surface and remove 8. Remove lock washer and lock screw. the studs by using a hammer. 9. Use wrench J–36827, remove hub nut. 411RS004 901RW054 10. Remove hub and disc assembly. Inspection and Repair 11.
  • Page 483 DRIVE SHAFT SYSTEM 4C–13 D Insert a wheel stud using a hammer. 3. Use installer J–36829 and grip J–8092, then install the inner bearing by driving it into the hub. Be sure the wheel stud is started squarely and seats completely. 901RW055 4.
  • Page 484 4C–14 DRIVE SHAFT SYSTEM 5. Apply grease (NLGI No.2 or equivalent) to the lip 8. Install hub nut. portion, then install oil seal by using installer J–36830 Turn to the place where there is a chamfer in the and grip J–8092. tapped hole to the outer side, then attach the nut by using front hub nut wrench J–36827.
  • Page 485 DRIVE SHAFT SYSTEM 4C–15 9. Install lock washer and lock screw in the following 12. Install hub cap. manner. 13. Tighten the bolts to the specified torque. D Turn the side with larger diameter of the tapered Torque: 59 N·m (43 lb ft) bore to the vehicle outer side, then attach the washer.

  • Page 486: Main Data And Specifications

    4C–16 DRIVE SHAFT SYSTEM Main Data and Specifications Torque Specifications E04RW001...

  • Page 487: Special Tools

    DRIVE SHAFT SYSTEM 4C–17 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–36827 Wrench; Hub nut J–36829 Installer; Inner bearing J–36828 Installer; Outer bearing J–36830 Installer; Oil seal...

  • Page 488: Front Drive Shaft Joint

    4C–18 DRIVE SHAFT SYSTEM Front Drive Shaft Joint Front Drive Shaft Joints Replace- 1. Open filler plug and make sure that the oil is up to the plug port. ment If the level oil is low, replenish with gear oil GL–5 D Refer to Front Drive Axle Assembly Replacement in grade.

  • Page 489: Front Axle Drive Shaft

    DRIVE SHAFT SYSTEM 4C–19 Front Axle Drive Shaft Front Axle Drive Shaft and Associated Parts 412RW003 Legend (13) Spacer (1) Axle Case and Differential (14) Ball (2) DOJ Case Assembly (15) Snap Ring (3) Snap Ring (16) Ball Retainer (4) Bearing (17) Ball Guide (5) Snap Ring (18) Band...

  • Page 490: Disassembly

    4C–20 DRIVE SHAFT SYSTEM Disassembly 4. Remove drive shaft joint assembly. 5. Using snap ring pliers, remove the snap ring. NOTE: For the left side, follow the same steps as right side. 1. Raise the hooked end of the band (1) with a screwdriver or equivalent.

  • Page 491: Inspection And Repair

    DRIVE SHAFT SYSTEM 4C–21 8. Using snap ring pliers, remove the snap ring (1) Inspection and Repair fastening the ball retainer to the center shaft. Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection.

  • Page 492: Reassembly

    4C–22 DRIVE SHAFT SYSTEM Reassembly 12. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft. 1. Install DOJ case to bracket. 2. Install oil seal and fix snap ring. 3. Install bearing and fix snap ring. 4.
  • Page 493 DRIVE SHAFT SYSTEM 4C–23 14. Install spacer. 18. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so 15. Install snap ring. that it equals atmospheric pressure. 16. Enclose 150g of the specified grease in DOJ case, then install drive shaft joint assembly.

  • Page 494: Shift On The Fly System

    4C–24 DRIVE SHAFT SYSTEM Shift On The Fly System Shift On The Fly System and Associated Parts 412RW004 Legend (8) Needle Bearing (1) Filler Plug (9) Clutch Gear (2) Bolt (10) Sleeve (3) Oil Seal (11) Housing (4) Snap Ring(External) (12) Front Axle Drive Shaft (LH side)with Bracket (5) Inner Shaft Bearing (13) Bolt...
  • Page 495 DRIVE SHAFT SYSTEM 4C–25 6. Remove clutch gear. 10. Remove inner shaft bearing by using a remover J–37452 and press. 7. Remove snap ring from front axle case by using snap ring pliers. NOTE: Be careful not to damage the shaft. 412RW017 412RW015 8.

  • Page 496: Inspection And Repair

    4C–26 DRIVE SHAFT SYSTEM Inspection and Repair Inner Shaft Run–Out With both end centers supported, rotate the shaft slowly Inspect the removed parts. If there are abnormalities and measure deflection with a dial gauge. such as wear and damage, take corrective action or replace.
  • Page 497 DRIVE SHAFT SYSTEM 4C–27 Sleeve Condition Clutch Gear Condition Check and see that there is no wear, damage, or cracking Check and see that there is no wear, damage, cracking, in the sleeve. or any other abnormality in the clutch gear. NOTE: Close inspection of the groove and inner gear are Clutch Gear Function required because those are important parts.
  • Page 498 4C–28 DRIVE SHAFT SYSTEM Actuator Check and see that there is no damage, cracking, or other abnormality. Functional Check 412RW007 Disconnect the shift position switch and make sure of function with a vacuum of –400 mmHg applied to Ports A and B, in accordance with the table below.
  • Page 499 DRIVE SHAFT SYSTEM 4C–29 2. Be careful not to permit the entry of water or dust into 2. Force a new needle bearing into inner shaft by using a the ports of the actuator. installer J–41694 and grip J–8092. Dimensional Check Measure illustrated sizes 1, 2, and 3.
  • Page 500 4C–30 DRIVE SHAFT SYSTEM 6. Install snap ring (internal) in the groove of front axle 10. Tighten bolts to specified torque. case. Torque: 116N·m(85 lb ft) NOTE: Be sure to install the snap ring properly. 11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to specified torque.

  • Page 501: Main Data And Specifications

    DRIVE SHAFT SYSTEM 4C–31 Main Data and Specifications General Specifications Front drive axle oil capacity 1.4 liter (1.48 US qt)(Differential) 0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly) Type of lubricant GL–5 (Multi grade type) Refer to chart in General Information Axle shaft type Constant velocity joint(Birfield joint type and double offset joint) Torque Specifications...

  • Page 502: Special Tools

    4C–32 DRIVE SHAFT SYSTEM Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–39378 Remover and Installer; J–8092 Front Axle mount Grip bushing J–37452 Remover and Installer; Inner shaft bearing J– 26941 Remover;Bearing needle J–2619–01 Hammer; Sliding J–41693 Installer;...

  • Page 503: Front Propeller Shaft

    DRIVE SHAFT SYSTEM 4C–33 Front Propeller Shaft General Description Since the propeller shaft is balanced carefully, welding or Alignment marks should be applied to each propeller any other modifications are not permitted. shaft before removal. 401RW002...

  • Page 504: Front Propeller Shaft And Associated Parts 4C-34

    4C–34 DRIVE SHAFT SYSTEM Front Propeller Shaft and Associated Parts 401RW058 Legend (4) Front Propeller Shaft (with TOD) (1) Bolt, Nut and Washer (Front Axle Side) (5) Coupling (2) Front Propeller Shaft (6) LJ Constant Velocity Joint (3) Bolt, Nut and Washer (Transfer Side) (7) BJ Constant Velocity Joint Removal 1.

  • Page 505: Installation

    DRIVE SHAFT SYSTEM 4C–35 401RW053 401RW051 Installation NOTE: Never install the shaft assembly backwards. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 1.

  • Page 506: Disassembly (Except Tod 4 4)

    4C–36 DRIVE SHAFT SYSTEM Disassembly (Except TOD 4 4) 401RW057 Legend (2) Seal (1) Sleeve Yoke (3) Tube Assembly 1. Apply alignment marks (1) on the sleeve yoke and 2. Remove seal. tube assembly then remove sleeve yoke. 3. Remove tube assembly. 401RW056...

  • Page 507: Universal Joint Disassembly

    DRIVE SHAFT SYSTEM 4C–37 Universal Joint Disassembly 401RW055 Legend (3) Snap Ring (1) Flange Yoke (4) Needle Roller Bearing (2) Spider (5) Grease Fitting 1. Apply alignment marks (1) on the yokes of the 2. Tap out the needle roller bearing by gently striking the universal joint, then remove snap ring.

  • Page 508: Inspection And Repair

    4C–38 DRIVE SHAFT SYSTEM 3. Make sure of proper position for reinstallation by applying setting marks, then remove spider . Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection. NOTE: When any part of the journal assembly (spider, needle roller bearing) requires replacement, be sure to replace the entire assembly.
  • Page 509 DRIVE SHAFT SYSTEM 4C–39 Play in Universal Joint Limit: Less than 0.1 mm (0.004 in) 401RW049 Boot of Constant Velocity Joint Check the boot (2) for crack, damage and grease leak, 401RS010 and the boot band (1) for loosening and damage. Check Constant Velocity Joint the both sides of the joint and make sure that there is no leak of grease from the cover press-in parts(3).
  • Page 510 4C–40 DRIVE SHAFT SYSTEM 2. Set a dial gage at right angle near the inner circumference and check the run-out of the flange. Limit: 0.15 mm (0.006 in) 401RW047 Front Axle Flange Run-out 1. Set a dial gage at right angle near the outer 401RW045 circumference of the flange face and check the 3.

  • Page 511: Universal Joint Reassembly

    DRIVE SHAFT SYSTEM 4C–41 Universal Joint Reassembly 4. Align setting marks (1) and join the yokes. 1. Install spider to flange yoke. Be sure to install the spider by aligning the setting marks made during disassembly. 2. Apply molybdenum–disulfide grease multi–purpose type grease NLGI No.

  • Page 512: Reassembly (Except Tod 4 4)

    4C–42 DRIVE SHAFT SYSTEM Reassembly (Except TOD 4 4) 401RW057 Legend (2) Seal (1) Sleeve Yoke (3) Tube Assembly 1. Discard used seal and install new one. 2. Align the alignment marks and install tube assembly to sleeve yoke.

  • Page 513: Main Data And Specifications

    DRIVE SHAFT SYSTEM 4C–43 Main Data and Specifications General Specifications Engine 6VE1(3.5 L) Transmission A/T with TOD Hollow steel tube with yoke and spider type universal Hollow steel tube with Construction joints. constant velocty joints. Outside diameter 40.0 mm (1.57 in) 40.0 mm (1.57 in) 40.0 mm (1.57 in) Length...

  • Page 514: Rear Propeller Shaft

    4C–44 DRIVE SHAFT SYSTEM Rear Propeller Shaft General Description Since the propeller shaft is balanced carefully, welding or Alignment marks should be applied to each propeller any other modifications are not permitted. shaft before removal. 401RW003 Rear Propeller Shaft and Associated Parts 401RW059 Legend (2) Rear Propeller Shaft...

  • Page 515: Installation

    DRIVE SHAFT SYSTEM 4C–45 401RS023 3. Remove bolt, nut and washer (Rear axle side). 4. Remove bolt, nut and washer (Transfer side). 5. Remove rear propeller shaft. Installation NOTE: Never install the shaft assembly backwards. 1. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft.

  • Page 516: Disassembly

    4C–46 DRIVE SHAFT SYSTEM Disassembly 401RW057 Legend (2) Seal (1) Sleeve Yoke (3) Tube Assembly 1. Apply alignment marks (1) on the sleeve yoke and 2. Remove seal. tube assembly then remove sleeve yoke. 3. Remove tube assembly. 401RW056...

  • Page 517: Universal Joint Disassembly

    DRIVE SHAFT SYSTEM 4C–47 Universal Joint Disassembly 401RW054 Legend (3) Snap Ring (1) Flange Yoke (4) Needle Roller Bearing (2) Spider with Grease Fitting (5) Grease Fitting 1. Apply alignment marks (1) on the yokes of the 2. Tap out the needle roller bearing by gently striking the universal joint, then remove snap ring.

  • Page 518: Inspection And Repair

    4C–48 DRIVE SHAFT SYSTEM 3. Make sure of proper position for reinstallation by applying setting marks, then remove spider with grease fitting. Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection.

  • Page 519: Universal Joint Reassembly

    DRIVE SHAFT SYSTEM 4C–49 Play in Universal Joint Limit: Less than 0.1 mm (0.004 in) 401RS012 4. Align setting marks (1) and join the yokes. NOTE: Assemble the spider and spline yoke so that their grease fittings are arranged on the same side. 401RS010 Universal Joint Reassembly 1.

  • Page 520: Reassembly

    4C–50 DRIVE SHAFT SYSTEM Reassembly 401RW057 Legend (2) Seal (1) Sleeve Yoke (3) Tube Assembly 1. Discard used seal and install new one. 2. Align the alignment marks and install tube assembly to sleeve yoke.

  • Page 521: Main Data And Specifications

    DRIVE SHAFT SYSTEM 4C–51 Main Data and Specifications General Specifications Engine 6VE1(3.5 L) Transmission A/T with TOD Construction Hollow steel tube with yoke and spider type universal joints. Outside diameter 68.9 mm (2.71 in) 68.9 mm (2.71 in) 68.9 mm (2.71 in) Length 1093 mm (43.03 in) 1093 mm (43.03 in)
  • Page 522 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.

  • Page 523: General Description

    4D1–2 TRANSFER CASE (STANDARD TYPE) General Description M/T model A07RW019...
  • Page 524 TRANSFER CASE (STANDARD TYPE) 4D1–3 A/T model A07RW001 The transfer case is used to provide a means of providing power flow to the front axle. The transfer case also provides a means of disconnecting the front axle, providing better fuel economy and quieter operation when the vehicle is driven on improved roads where four wheel drive is not required.

  • Page 525: Transfer Rear Oil Seal

    4D1–4 TRANSFER CASE (STANDARD TYPE) Transfer Rear Oil Seal Removal 1. Disconnect the rear propeller shaft from the transfer case side. 2. Remove end nut and rear companion flange, use the companion flange holder J–8614–11 to remove the end nut. 220RS016 4.

  • Page 526: Transfer Case Assembly

    TRANSFER CASE (STANDARD TYPE) 4D1–5 8. Connect the rear propeller shaft to the transfer case and tighten to the specified torque. Torque: 63 N·m 46 (lb ft) 266RW002 Transfer Case Assembly Removal 10. Remove transfer control lever. 11. Disconnect the 4WD switch and speed sensor NOTE: Before removing transmission &...
  • Page 527 4D1–6 TRANSFER CASE (STANDARD TYPE) 2. Tighten the transmission–transfer bolt to the 3. Tighten the exhaust pipe to exhaust manifold bolt to specified torque. the specified torque. Torque: 46 N·m (34 lb ft) Torque: 67 N·m (49 lb ft) 4. Tighten the exhaust pipe flange bolt to the specified torque.

  • Page 528: Transfer Rear Case Assembly

    TRANSFER CASE (STANDARD TYPE) 4D1–7 Transfer Rear Case Assembly Removal 10. Pull 2WD–4WD actuator assembly with 2WD–4WD shift rod. 1. Remove the speedometer sensor. 2. Remove the plate. 3. Remove the speedometer driven gear bushing and driven gear. NOTE: Apply a reference mark to the driven gear bushing before removal.

  • Page 529: Installation

    4D1–8 TRANSFER CASE (STANDARD TYPE) 11. Off set the actuator assembly. 2. Install transfer case assembly and apply the recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer rear case fitting faces. 220RW028 12. Remove the actuator assembly. 220RS017 3.
  • Page 530 TRANSFER CASE (STANDARD TYPE) 4D1–9 6. Join the rod grooves of 2WD–4WD actuator 11. Install rear companion flange. assembly (12) and shift rod (11). 12. Install front companion flange, use the companion flange holder J–8614–11 to tighten the flange nuts to the transfer case.
  • Page 531 4D1–10 TRANSFER CASE (STANDARD TYPE) 19. Install the plate (6) to the transfer rear case and tighten to the specified torque. Torque: 15 N·m (11 lb ft) 20. Install the speedometer sensor and tighten to the specified torque. Torque: 27 N·m (20 lb ft) 266RW002 15.

  • Page 532: Disassembly

    TRANSFER CASE (STANDARD TYPE) 4D1–11 Disassembly 226RW131 Legend (5) Bearing Snap Ring (1) Rear Output Shaft Assembly (6) Ball (2) Rear Output Shaft (7) Speedometer Drive Gear (3) Bearing Snap Ring (8) Ball Bearing (4) Ball Bearing (9) Transfer Rear Case (with oil seal) 1.

  • Page 533: Inspection And Repair

    4D1–12 TRANSFER CASE (STANDARD TYPE) 2. Remove the rear output shaft assembly from the Reassembly transfer rear case. 1. Install transfer rear case (with oil seal). 3. Remove ball bearing, use a bench press and the Oil seal replacement bearing remover J–22912–01 to remove the ball D Remove the oil seal from the transfer rear case.
  • Page 534 TRANSFER CASE (STANDARD TYPE) 4D1–13 6. Install speedometer drive gear. 226RS064 7. Install ball bearing, use the ball bearing installer J–37223 to install the ball bearing. 226RS065 8. Install the rear output shaft assembly to the transfer rear case. 9. Install bearing snap ring. NOTE: The snap ring must be fully inserted into the transfer rear case snap ring groove.

  • Page 535: Detent, Shift Arm, And Interlock Pin (Transfer Case Assembly)

    4D1–14 TRANSFER CASE (STANDARD TYPE) Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly) Disassembled View 262RW010 Legend (9) Shift Arm (1) Transfer Case (10) 2WD–4WD Shift Rod (2) Detent Ball, Spring and Plug (11) Spring Pin and Bridge (3) Spring (12) Select Rod Assembly (4) Interlock Pin (13) Spring Pin...
  • Page 536 TRANSFER CASE (STANDARD TYPE) 4D1–15 2. Remove spring pin and bridge, use a spring pin 10. Remove spring, use a magnetic tool to remove the remover to remove the spring pin from the bridge. interlock pin from the transfer case. 262RW011 262RS005 3.

  • Page 537: Inspection And Repair

    4D1–16 TRANSFER CASE (STANDARD TYPE) Inspection and Repair Refer to “TRANSFER CASE ASSEMBLY” in this section for inspection and repair. Reassembly 1. Install transfer case. 2. Install shift block. 3. Install shift arm. 4. Install high–low shift rod. 5. Engage the High–Low sleeve with the 4H (1) side. 6.
  • Page 538 TRANSFER CASE (STANDARD TYPE) 4D1–17 16. Engage the 2WD–4WD sleeve with the 4WD side and install the spring pin. 262RW022 17. Install spring pin and bridge. 18. Install detent ball, spring and plug and tighten the plug to the specified torque. Torque: 25 N·m (18 lb ft)

  • Page 539: Transfer Case Assembly

    4D1–18 TRANSFER CASE (STANDARD TYPE) Transfer Case Assembly Disassembled View 226RW132 Legend (22) Counter Gear (1) Transfer Case (with oil seal) (23) Sub–Gear (anti–lash plate) (2) Bearing Snap Ring (24) Belleville Spring (3) Front Output Gear Assembly (25) Spacer (4) Ball Bearing (26) Ball Bearing (5) Front Output Shaft (27) Snap Ring...

  • Page 540: Disassembly

    TRANSFER CASE (STANDARD TYPE) 4D1–19 Disassembly 7. Remove the input shaft assembly from the transfer case. 1. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring. 2. Remove ball bearing, use a bearing remover J–37217 and puller J–37487 to remove the ball bearing.
  • Page 541 4D1–20 TRANSFER CASE (STANDARD TYPE) 11. Remove bearing collar. 17. Remove front output gear assembly, use a pair of snap ring pliers to expand the bearing snap ring and use a plastic hammer to tap the front output gear assembly free. 226RS071 12.

  • Page 542: Inspection And Repair

    TRANSFER CASE (STANDARD TYPE) 4D1–21 30. Disassemble the 2WD–4WD clutch hub and sleeve 37. Remove ball bearing, use a bench press and the assembly. bearing remover J–22912–01 to remove the ball bearing. D Springs (1) 38. Remove snap ring, use a pair of snap ring pliers to D Inserts (2) remove the snap ring.
  • Page 543 4D1–22 TRANSFER CASE (STANDARD TYPE) 2. If the measured value exceeds the specified limit, the Bearings gear must be replaced. 1. Inspect the condition of all the needles and ball Gear inside diameter bearings. Wash bearings thoroughly in a cleaning solvent.
  • Page 544 TRANSFER CASE (STANDARD TYPE) 4D1–23 Block Ring and Insert Clearance Clutch Hub and Insert Clearance 1. Use a vernier caliper to measure the clearance 1. Use a thickness gauge to measure the clearance between the block ring and the insert. between the clutch hub and the insert.
  • Page 545 4D1–24 TRANSFER CASE (STANDARD TYPE) 2. If the measured value is less than the specified limit, the detent spring must be replaced. Detent spring free length Detent ball Standard : 23.4 mm (0.921 in) Limit : 22.8 mm (0.898 in) Interlock pin Standard : 1.59 mm (0.063 in) Limit : 1.53 mm (0.060 in)

  • Page 546: Reassembly

    TRANSFER CASE (STANDARD TYPE) 4D1–25 Reassembly 1. Install transfer case (with oil seal). Input shaft oil seal (1) replacement 1. Remove the oil seal from the transfer case. 2. Apply engine oil to the oil seal outer surfaces. 3. Apply recommended grease (BESCO L2) or equivalent to the oil seal lip.
  • Page 547 4D1–26 TRANSFER CASE (STANDARD TYPE) 3. Measure the sub–gear preload. Snap ring availability: Preload : 59–98 N (13–22 lb) Thickness Color–coding 1.50 mm (0.059 in) White 1.55 mm (0.061 in) Yellow 1.60 mm (0.063 in) Blue 8. Use a pair of snap ring pliers to install the snap ring to the counter gear.
  • Page 548 TRANSFER CASE (STANDARD TYPE) 4D1–27 16. Assemble the clutch sleeve and hub assembly. 18. Install a new stopper plate and the clutch sleeve and hub assembly to the front output shaft. 226RW140 17. Engage the springs in the same insert with the open 226RW135 ends away from each other.
  • Page 549 4D1–28 TRANSFER CASE (STANDARD TYPE) 27. Install belleville spring. (M/T) 32. Install bearing snap ring and select a snap ring that will allow the minimum axial play. 28. Install spacer and apply engine oil to the thrust surfaces of the sub–gear, the belleville spring, and the Clearance : 0–0.1 mm (0–0.004 in) spacer.
  • Page 550 TRANSFER CASE (STANDARD TYPE) 4D1–29 33. Use a pair of snap ring pliers to install the snap ring to 39. Install ball. the output shaft. 40. Install bearing collar. Sub gear (anti lash plate) preload (M/T) 41. Install needle bearing. 1.
  • Page 551 4D1–30 TRANSFER CASE (STANDARD TYPE) 50. Install ball bearing, use a suitable drift and hammer to install the ball bearing. 226RS079 51. Install bearing snap ring.

  • Page 552: Main Data And Specifications

    TRANSFER CASE (STANDARD TYPE) 4D1–31 Main Data and Specifications General Specifications Type Synchronized type gears shifting between the 2 and 4 wheel drive mode. Constant mesh type gears shifting between “low” and “high”. Control method Remote control with the gear shift lever on the floor for gear shifting between “low and high”...
  • Page 553 4D1–32 TRANSFER CASE (STANDARD TYPE) E07RW009...
  • Page 554 TRANSFER CASE (STANDARD TYPE) 4D1–33 E07RW010...

  • Page 555: Special Tools

    4D1–34 TRANSFER CASE (STANDARD TYPE) Special Tools PART NO. PART NO. ILLUSTRATION ILLUSTRATION PART NAME PART NAME J–22912–01 J–38594 Bearing Front output shaft oil remover/installer seal installer J–38592 J–39208 Transfer case oil seal Rear oil seal installer installer J–37219 J–37486–A Mainshaft nut wrench Bearing installer adapter J–37223...
  • Page 556 TRANSFER CASE (STANDARD TYPE) 4D1–35 PART NO. ILLUSTRATION PART NAME J–37487 Puller J–8092 Driver handle...
  • Page 557 WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application. RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out...

  • Page 558: Transfer Case Assembly

    4D2–2 TRANSFER CASE (TOD) Transfer Case Assembly Removal F07RW025 1. Disconnect the battery cable (-). 2. Remove transfer protector. 3. Remove rear propeller shaft. 4. Remove front propeller shaft. 5. Remove center console.

  • Page 559: Installation

    TRANSFER CASE (TOD) 4D2–3 6. Uncouple the shift control rod from the select lever Installation assembly. Pay attention to the following points. 1. Apply grease (Besco L2) or equivalent to the input shaft spline. 256RW028 7. Place the select lever assembly near the end. 8.
  • Page 560 4D2–4 TRANSFER CASE (TOD) 3. Tighten the transfer case bolts (see the figure below). 261RW004 4. Tighten propeller shaft bolt. Torque : 63 N·m (46 lb ft)

  • Page 561: Transfer Rear Oil Seal

    TRANSFER CASE (TOD) 4D2–5 Transfer Rear Oil Seal Transfer Rear Oil Seal and Associated Parts 261RW005 Legend (1) Oil Seal (2) End Nut and Rear Companion Flange Removal 1. Uncouple the rear propeller shaft from the transfer case. 2. Using the flange holder J-8614-11, remove the end nut.
  • Page 562 4D2–6 TRANSFER CASE (TOD) 2. Using the oil seal installer J-42804, attach the oil seal. NOTE: When attaching the oil seal, pay attention to the direction. 260RW007 6. Connect the rear propeller shaft to the transfer case and tighten to the specified torque. Torque : 63 N·m 46 (lb ft) 261RW035 3.

  • Page 563: Tod Ecu

    TRANSFER CASE (TOD) 4D2–7 TOD ECU Removal Installation 1. Disconnect the battery cable (-). 1. Perform the removal step in reverse order. 2. Move the passenger seat forward and remove the second seat foot rest (1). 3. Unplug the connector from the ECU (2). 4.

  • Page 564: Unit Repair

    4D2–8 TRANSFER CASE (TOD) Unit Repair Inspection Power GND Check that there is a continuity between the power GND Before disassembling and after assembling, check the pin (terminal 7) and transfer case. If not, replace the following items on the transfer connector terminals. grounding wire.

  • Page 565: Transfer Case

    TRANSFER CASE (TOD) 4D2–9 Transfer Case Disassembled View 266RW004 Legend (4) Spring Pin (1) Front Companion Flange (5) Transfer Case Assembly (2) 4H and 4L Switch, Grounding Cable, and (6) Transfer Cover Assembly Center Connector (7) Rear Companion Flange (3) Offset Lever Disassembly 1.

  • Page 566: Reassembly

    4D2–10 TRANSFER CASE (TOD) 6. Remove the offset lever set bolt on the right side. 8. Remove the offset lever. 261RW015 261RW017 7. Remove the offset lever lock spring pin. 9. Remove the sixteen bolts and detach the transfer cover assembly from the transfer cable assembly. NOTE: When removing the spring pin, pay attention to the recess position of the pin.
  • Page 567 TRANSFER CASE (TOD) 4D2–11 2. Tighten the sixteen bolts with the specified torque. 10. Using the punch J-39209, securely stake the flange nut at two places Torque : 31 N·m (23 lb ft) NOTE: Check the staked flange nut is free from cracks. 3.

  • Page 568: Transfer Cover Assembly

    4D2–12 TRANSFER CASE (TOD) Transfer Cover Assembly Disassembled View 261RW007 Legend (4) Speed Gear and Tone Wheel (1) Coil Assembly (5) Ball Bearing (2) Snap Ring (6) Transfer Cover Assembly (3) Ball Bearing (7) Front and Rear Speed Sensors Disassembly 1.
  • Page 569 TRANSFER CASE (TOD) 4D2–13 2. Remove ball bearing. 5. Using a terminal pull-out tool or an equivalent tool, push down the lock to unlatch the terminal for the coil 3. Strike the speed gear and tone wheel with a rod or assembly, and pull the terminal out.

  • Page 570: Reassembly

    4D2–14 TRANSFER CASE (TOD) 7. Using the bearing remover J-42805 and slide Reassembly hammer J-2619-01, remove the ball bearing for the 1. Remove the oil seal from the transfer cover assembly. front output shaft. 2. Apply oil to the circumference of the new oil seal and fill the lip with grease (Besco L2 or equivalent).
  • Page 571 TRANSFER CASE (TOD) 4D2–15 7. Mount the coil assembly and tighten the set nuts with the specified torque. Torque : 10 N·m (87 lb in) 8. Plug the terminal in the central connector. NOTE: Pay attention not to damage other terminals. 9.

  • Page 572: Transfer Case Assembly Clutch Pack And Clutch Cam

    4D2–16 TRANSFER CASE (TOD) Transfer Case Assembly Clutch Pack and Clutch Cam Disassembled View 266RW006 Legend (5) Wave Spring (1) Clutch Pack Assembly (6) Cam Pulley (2) Insulator Washer (7) Cam Ball (3) Armature Plate (8) Cam and Coil Housing (4) Snap Ring (9) Thrust Bearing Disassembly...
  • Page 573 TRANSFER CASE (TOD) 4D2–17 4. Remove cam pulley. 5. Remove wave spring. 6. Using snap ring pliers, remove the snap ring. NOTE: Pay attention not to damage the snap ring. 266RW009 7. Remove the armature plate. 8. Remove the insulator washer. 9.
  • Page 574 4D2–18 TRANSFER CASE (TOD) Sprocket and Mechanical Lock Disassembled View 266RW008 Legend (7) Lock-up Fork (1) Strainer (8) Chain (2) Hose (9) Lower Drive Sprocket (3) Oil Pump Assembly (10) Front Tone Wheel (4) Thrust Washer (11) Drive Sprocket (5) Mechanical Lock Hub (12) Sprocket Spacer (6) Lock-up Sleeve Disassembly...
  • Page 575 TRANSFER CASE (TOD) 4D2–19 5. Remove the drive sprocket, lower drive sprocket, and chain together from the front and rear output shafts. 266RW010 6. Remove mechanical lock hub. 7. Remove lock-up fork. 8. Remove the spring retainer from the connection between rail shaft and lock-up fork.

  • Page 576: Output Shafts And Shift Control Shaft

    4D2–20 TRANSFER CASE (TOD) Output Shafts and Shift Control Shaft Disassembled View 261RW010 Legend (10) Cam Assembly (1) Transfer Case Assembly (11) Snap Ring (2) Detent Spring (12) Washer (3) Front Output Shaft (13) Cam (4) Reduction Hub (14) Cam Pilot Block (5) Output Shaft (15) Shifter Shaft Assembly (6) Lock-up Roll Assembly...
  • Page 577 TRANSFER CASE (TOD) 4D2–21 Disassembly 6. Remove the spring pin that fixes the reduction fork. 1. Remove output shaft. 261RW020 7. Remove the reduction fork. 266RW011 8. Remove the lock-up roll. 2. Remove detent spring. 9. Using snap ring pliers, remove the snap ring. 3.
  • Page 578 4D2–22 TRANSFER CASE (TOD) 13. Using snap ring pliers, attach the snap ring. 261RW021 14. Remove the reduction lever assembly. 15. Remove the snap ring. 16. Remove the shifter lever shaft. 17. Remove the front output shaft. 266RW012 18. Remove transfer case assembly.

  • Page 579: Disassembled View

    TRANSFER CASE (TOD) 4D2–23 Transfer Case Disassembled View 265RW002 Legend (7) Ball Bearing (1) Transfer Case (8) Spring Ring (2) Ball Bearing (9) Thrust Plate (3) Ring Gear (10) Carrier Assembly (4) Snap Ring (11) Snap Ring (5) Input Shaft and Carrier Assembly (12) Circular Hub (6) Snap Ring...

  • Page 580: Disassembly

    4D2–24 TRANSFER CASE (TOD) Disassembly 4. Remove the snap ring from the transfer case. 1. Remove ball bearing (for front output shaft). 2. Open the snap ring from the gap on the carrier assembly. 261RW036 5. Using snap ring pliers, remove the snap ring before the ball bearing.
  • Page 581 TRANSFER CASE (TOD) 4D2–25 6. Using the bearing remover J-22912-01, remove the 10. Remove the circular hub. ball bearing from the input shaft. 11. Remove the snap ring before the ring gear. 265RW004 261RW025 7. Remove the thrust plate. 12. Using the special tool J-42806, remove the ring gear. 8.

  • Page 582: Inspection And Repair

    4D2–26 TRANSFER CASE (TOD) D If the measurement exceeds the limit, replace the reduction hub. Standard : 3.05-3.30 mm (0.120-0.130 in) Allowable limit : 2.5 mm (0.098 in) 265RW007 Inspection and Repair When wear, damage, or any other defects are observed during the inspection, the part or parts must be repaired or replaced.
  • Page 583 TRANSFER CASE (TOD) 4D2–27 Reduction Fork Bearing Check the reduction fork and shaft for wear, distortion, Check the profile of the needle, roller, ball, and thrust and scratches. If defects are observed, replace the bearings. Wash the bearings with clean detergent parts.
  • Page 584 4D2–28 TRANSFER CASE (TOD) Tension of Lock-up Fork Spring Multi Plate Disk Clutch D If the measurement exceeds the limit, replace the D If the burned, mirror-surfaced clutch facing, or spring. (When compressed to 41.4 mm) scraping is observed on the clutch plates, clutch housing, armature plate, and insulator washer, Standard : 27.1-33.8 N {2.76-3.45 kg} replace the part or parts.
  • Page 585 TRANSFER CASE (TOD) 4D2–29 Cam Pulley, Cam Ball, and Cam&Coil Housing D Check the cam balls and cam for excessive wear or damage. If defective, replace the parts. 4H and 4L switches. 261RW049 Switch 4H Switch 4L Switch Signal Signal Stroke correspon ding...

  • Page 586: Transfer Case

    4D2–30 TRANSFER CASE (TOD) Transfer Case Disassembled View 265RW002 Legend (7) Ball Bearing (1) Transfer Case (8) Spring Ring (2) Ball Bearing (9) Thrust Plate (3) Ring Gear (10) Carrier Assembly (4) Snap Ring (11) Snap Ring (5) Input Shaft and Carrier Assembly (12) Circular Hub (6) Snap Ring Reassembly...
  • Page 587 TRANSFER CASE (TOD) 4D2–31 3. Using the front output shaft oil seal installer J-42807, 5. Using the special tool J-42809, press-fit the ring gear. attach the oil seal to the transfer case. Pay attention to the following points. D Identify the correct direction of gear. D Do not damage the gear.
  • Page 588 4D2–32 TRANSFER CASE (TOD) 9. Mount the carrier assembly to the transfer case. 14. Using the snap ring pliers, open the snap ring from the gap on the input shaft and carrier assembly and 10. Check the direction of thrust plate and mount it to the securely attach the part.

  • Page 589: Output Shafts And Shift Control Shaft

    TRANSFER CASE (TOD) 4D2–33 Output Shafts and Shift Control Shaft Disassembled View 261RW010 Legend (10) Cam Assembly (1) Transfer Case Assembly (11) Snap Ring (2) Detent Spring (12) Washer (3) Front Output Shaft (13) Cam (4) Reduction Hub (14) Cam Pilot Block (5) Output Shaft (15) Shifter Shaft Assembly (6) Lock-up Roll Assembly...
  • Page 590 4D2–34 TRANSFER CASE (TOD) 2. Mount the front output shaft to the transfer case. 4. Mount the cam to the cam pilot. 5. Attach the washer to the cam pilot block and fix the washer with the snap ring. 266RW012 3.
  • Page 591 TRANSFER CASE (TOD) 4D2–35 8. Mount the lock-up assembly and reduction hub to together to transfer case assembly. 9. Mount the shifter shaft assembly. 261RW019 10. Tighten the cam pilot block set bolts to the specified torque. Torque : 12 N·m (104 lb in) 11.

  • Page 592: Sprocket And Mechanical Lock

    4D2–36 TRANSFER CASE (TOD) Sprocket and Mechanical Lock Disassembled View 266RW008 Legend (7) Lock-up Pork (1) Strainer (8) Chain (2) Hose (9) Lower Drive Sprocket (3) Oil Pump Assembly (10) Front Tone Wheel (4) Thrust Washer (11) Drive Sprocket (5) Mechanical Lock Hub (12) Sprocket Spacer (6) Lock-up Sleeve Reassembly...
  • Page 593 TRANSFER CASE (TOD) 4D2–37 5. Attach the spring to the lock-up fork. 6. Mount the lock-up sleeve and fork together to the output shaft and shifter roll assembly. 7. Mount the spring retainer to the lock-up fork. 261RW018 8. Install mechanical lock hub. 9.

  • Page 594: Clutch Pack And Clutch Cam

    4D2–38 TRANSFER CASE (TOD) Clutch Pack and Clutch Cam Disassembled View 266RW006 Legend (5) Wave Spring (1) Clutch Pack Assembly (6) Cam Pulley (2) Insulator Washer (7) Cam Ball (3) Armature Plate (8) Cam and Coil Housing (4) Snap Ring (9) Thrust Bearing Reassembly 1.
  • Page 595 TRANSFER CASE (TOD) 4D2–39 4. Using snap ring pliers, attach the snap ring. 266RW009 5. Install the wave spring. 6. Install the cam pulley. 7. Place a ball on each groove of the cam pulley. 266RW013 8. Install the cam and coil housing. 9.

  • Page 596: Main Data And Specifications

    4D2–40 TRANSFER CASE (TOD) Main Data and Specifications Leading Particulars Type Transfer case with low range reduction mechanisn Rear wheel drive Electronically controlled torque split four wheel drive Low-speed mechanical lock-up four wheel drive Control system Floor direct control Gear ratio 1.000 2.480 Oil quantity, Lit...
  • Page 597 TRANSFER CASE (TOD) 4D2–41 E07RW012...

  • Page 598: Special Tools

    4D2–42 TRANSFER CASE (TOD) Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–8614–11 J–42806 Flange Holder Ring Gear Replacer J–42807 J–42804 Front Out Oil Seal Rear Oil Seal Installer Installer J–42808 J–39209 Input Shaft Oil Seal Punch Installer J–42805...
  • Page 599 SECTION BRAKE CONTROL SYSTEM 5A–1 TROOPER BRAKES CONTENTS Brake Control System ....5A–1 Power-Assisted Brake System ... . 5C–1 Anti–lock Brake System .

  • Page 600: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    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.

  • Page 601: General Description

    BRAKE CONTROL SYSTEM 5A–3 General Description The Anti-lock Brake System (ABS) works on all four This system helps the driver maintain greater control of wheels. A combination of wheel speed sensor and the vehicle under heavy braking conditions. Electronic Hydraulic Control Unit (EHCU) can determine when a wheel is about to stop turning and adjust brake pressure to maintain best braking.

  • Page 602: Abs Warning Light

    5A–4 BRAKE CONTROL SYSTEM Motor: Drives the pump according to the signal from The G-sensor judges whether the friction coefficient of EHCU. road surface is low or high, and changes the EHCU’s Check Valve: Controls the brake fluid flow. operating system to ensure ABS control. ABS Warning Light Normal and Anti-lock Braking Under normal driving conditions, the Anti-lock Brake...

  • Page 603: General Diagnosis

    BRAKE CONTROL SYSTEM 5A–5 D If welding work is to be performed on the vehicle using Volts AC an electric arc welder, the EHCU and valve block connectors should be disconnected before the welding operation begins. Warning Light D The EHCU and valve block connectors should never be connected or disconnected with the ignition “ON”...

  • Page 604: Abs" Warning Light

    5A–6 BRAKE CONTROL SYSTEM 3. Slowly brake and stop the vehicle completely. to the trouble is stored in the EHCU. Only the ordinary brake system is available when the ABS is turned off. 4. Then restart the vehicle and accelerate to about 40 When the “ABS”...

  • Page 605: Basic Inspection Procedure

    BRAKE CONTROL SYSTEM 5A–7 Basic Inspection Procedure 1. Basic Inspection of System Brake Step Action Is the fluid level normal? Replenish with fluid. Go to Step 2 Go to Step 2 Does fluid leak? Repair. Go to Step 3 Go to Step 3 Is the booster functioning normal? Repair.

  • Page 606: Tech 2 Scan Tool

    5A–8 BRAKE CONTROL SYSTEM Tech 2 Scan Tool From 98 MY, Isuzu dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide. 901RW257 Legend (3) DLC Cable (1) PCMCIA Card (4) Tech–2...

  • Page 607: Getting Started

    Isuzu systems PCMCIA card. Follow the Tech 2, the following steps must be performed: operating procedure below. 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (3).
  • Page 608 5A–10 BRAKE CONTROL SYSTEM 060RX064...

  • Page 609: Data List

    BRAKE CONTROL SYSTEM 5A–11 Data List Display Content OK/NG Criteria for Data Battery Voltage Voltage Between 10–16.9V Brake Light Switch Open/Close Open(0V) when pedal is released Closed(12V) when pedal is depressed. Front Left Wheel Speed MPH(km/h) Start the vehicle and make sure of linear change in each Front Right Wheel Speed wheel speed.

  • Page 610: Ehcu Connector Pin-Out Checks

    5A–12 BRAKE CONTROL SYSTEM EHCU Connector Pin-out Checks D Disconnect Electronic Brake Control Module. D Perform checks with high impedance digital multimeter J-39200 or equivalent. Circuit to be Tested Ignition Multimeter Measure be- Nominal Value Note Switch Scale/Range tween Pin Position Number Ignition enable...

  • Page 611: Circuit Diagram

    BRAKE CONTROL SYSTEM 5A–13 Circuit Diagram D08RW033...
  • Page 612 5A–14 BRAKE CONTROL SYSTEM D08RW034...
  • Page 613 BRAKE CONTROL SYSTEM 5A–15 D08RW035...

  • Page 614: Connector List

    5A–16 BRAKE CONTROL SYSTEM Connector List D05RW002...
  • Page 615 BRAKE CONTROL SYSTEM 5A–17 D05RW003...

  • Page 616: Part Location

    5A–18 BRAKE CONTROL SYSTEM Part Location D08RW369 Legend (12) C–41 (1) F–2 (13) H–41, H–42 (2) F–3 (14) C–4 (3) I–9 (15) C–85 (4) C–63 (16) Relay & Fuse Box (X–15) (5) H–7, H–8, H–24, H–25 (17) H–12, H–15, H–16 (6) B–25 (18) C–39 (7) C–16...

  • Page 617: Symptom Diagnosis

    BRAKE CONTROL SYSTEM 5A–19 Symptom Diagnosis 4. Brake pedal feel is abnormal. 5. Braking sound (from EHCU) is heard while not The symptoms that cannot be indicated by the warning braking. light can be divided in the following five categories: These are all attributable to problems which cannot be de- 1.

  • Page 618: Chart Ta-1 Abs Works Frequently But Vehicle Does Not Decelerate (Use Tech 2)

    5A–20 BRAKE CONTROL SYSTEM Step Action Is the input of 4WD controller normal? Replace controller or repair harness. Go to Step 11 Go to Step 11 Reconnect all components and ensure all components are Repeat the “Basic properly mounted. diagnostic flow Was this step finished? chart.”...
  • Page 619 BRAKE CONTROL SYSTEM 5A–21 Chart A-3, TA-3 The Wheels Are Locked Step Action Is ABS working? Go to Step 2 Go to Step 6 Is vehicle speed under 10 km/h (6mph)? Normal. Go to Step 3 Is sensor output normal? (Chart C-1 or TC-1) Replace sensor or repair harness.

  • Page 620: Chart A-5,Ta-5 Braking Sound

    5A–22 BRAKE CONTROL SYSTEM Step Action Is the check harness/connector for suspended disconnection? Hydraulic system leakage or air entry (Refer to servicing “Leakage or brake fluid” ) Repair harness. Go to Step 7 Go to Step 7 Reconnect all components and ensure all components are Repeat the “Basic properly mounted.

  • Page 621: Diagnostic Trouble Codes

    BRAKE CONTROL SYSTEM 5A–23 Diagnostic Trouble Codes Choose and trace an appropriate flowchart by the numbers listed below to find fault and repair. Code Item Diagnosis Chart No. Start Code Normal — EHCU Function Abnormality in input/output, operational and control circuits Power Voltage Drop CLASS–2 Communication Line Ab- normality...

  • Page 622: Diagnosis By "Abs" Warning Light Illumination Pattern

    5A–24 BRAKE CONTROL SYSTEM Diagnosis By “ABS” Warning Light or if the warning light is actuated during driving, trouble should be diagnosed on a illumination pattern basis as Illumination Pattern follows: In the event that there is abnormality in the “ABS” warning light illumination pattern while the key is in the ON position Condition “ABS”...
  • Page 623 BRAKE CONTROL SYSTEM 5A–25 The DLC is located behind the driver side kick panel 350RT001 D Keep #12 terminal connected with #4 terminal or # 5 terminal (GND) during DTC display. (If #12 terminal is separated from #4 terminal or # 5 terminal (GND) during display, display will stop.) 2.
  • Page 624 5A–26 BRAKE CONTROL SYSTEM 4. Notes D If the following should occurs during Diagnostic Trouble Code (DTC) display the display will be discontinued. After initial check, the status that is under the control of ABS will be returned : – The vehicle starts (The wheels turn) or the brake pedal is depressed.

  • Page 625: Chart B-1 With The Key In The On Position (Before Starting The Engine). Warning Light (W/L) Is Not Activated

    BRAKE CONTROL SYSTEM 5A–27 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated. Step Action Is W/L fuse C-10 disconnected? Replace fuse. Go to Step 2 Go to Step 5 Is W/L burnt out? Replace W/L bulb.

  • Page 626: Chart B-3 Power Voltage Drop (Dtc 15)

    5A–28 BRAKE CONTROL SYSTEM Chart B-3 Power Voltage Drop (DTC 15) Step Action Is the battery voltage normal? (Battery capacity check) Charge or replace battery. Go to Step 2 Go to Step 2 1. Turn the key off. Check harness 2.

  • Page 627: Chart B-6 Abnormal Transmission Input (Dtc 23)

    BRAKE CONTROL SYSTEM 5A–29 Step Action Remove G sensor. Replace G sensor. Is the resistance between the G sensor connector terminals 1 and 2 within 1.0-2.0 kW when G sensor is horizontal? Go to Step 4 Go to Step 5 Measure resistance between G sensor connector terminals 1 and Harness between 2 within 4.0-6.0 kW when G sensor tilted to 30°...

  • Page 628: Chart B-7 Transfer Monitor (Dtc 24)

    5A–30 BRAKE CONTROL SYSTEM Step Action Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or Suspected 2,3,D,N and P(A/T)(Battery voltage 12V)? harness/ connector short power source/GND. Suspected shorted transmission SW. Transmission SW Fault found: trouble.

  • Page 629: Chart B-9 Ehcu Pump Valve And Valve Relay Circuit (Dtc 35)

    BRAKE CONTROL SYSTEM 5A–31 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35) Step Action 1. Turn the key off. Repair fuse and 2. Disconnect EHCU connector. harness EHCU 3. Measure voltage between EHCU connector terminal 14 and connector body ground.

  • Page 630: Chart B-12 Fr Isolation Solenoid Valve Abnormality (Dtc 43)

    5A–32 BRAKE CONTROL SYSTEM Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43) Step Action Was the “EHCU Connector Pin–out Checks” perfomed? Go to “EHCU Connector Pin-out Checks”. Go to Step 2 Is the EHCU connector free from damage or corrosion? Repair the connector.

  • Page 631: Chart B-15 Rear Dump Solenoid Valve Abnormality (Dtc 46)

    BRAKE CONTROL SYSTEM 5A–33 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46) Step Action Was the “EHCU Connector Pin–out Checks” perfomed? Go to “EHCU Connector Pin-out Checks”. Go to Step 2 Is the EHCU connector free from damage or corrosion? Repair the connector.

  • Page 632: Chart B-17 Fr Speed Sensor Disconnection (Dtc 52)

    5A–34 BRAKE CONTROL SYSTEM Chart B-17 FR Speed Sensor Disconnection (DTC 52) Step Action 1. Turn the key off. Check for faults 2. Disconnect EHCU connector. in harness 3. Measure the resistance between EHCU connector terminals 4 between speed and 5. sensor and EHCU.

  • Page 633: Chart B-19 Rr Speed Sensor Disconnection (Dtc 54)

    BRAKE CONTROL SYSTEM 5A–35 Chart B-19 RR Speed Sensor Disconnection (DTC 54) Step Action 1. Turn the key off. Check for faults 2. Disconnect EHCU connector. in harness 3. Measure the resistance between EHCU connector terminals 2 between speed and 3. sensor and EHCU.

  • Page 634: Chart B-20 Fl Speed Sensor Short Circuit (Dtc 61)

    5A–36 BRAKE CONTROL SYSTEM Chart B-20 FL Speed Sensor Short Circuit (DTC 61) Step Action 1. Turn the key off. 2. Disconnect EHCU connector 3. Measure the FL speed sensor resistance between EHCU connector terminals 20 and 21. Go to Step 2 Go to Step 3 Is the resistance between 1.3k and 1.9k ohms? Is there play in the sensor/sensor rotor?

  • Page 635: Chart B-21 Fr Speed Sensor Short Circuit (Dtc 62)

    BRAKE CONTROL SYSTEM 5A–37 Chart B-21 FR Speed Sensor Short Circuit (DTC 62) Step Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the FR speed sensor resistance between EHCU connector terminals 4 and 5. Go to Step 2 Go to Step 3 Is the resistance between 1.3k and 1.9k ohms? Is there play in the sensor/sensor rotor?

  • Page 636: Chart B-22 Rl Speed Sensor Short Circuit (Dtc 63)

    5A–38 BRAKE CONTROL SYSTEM Chart B-22 RL Speed Sensor Short Circuit (DTC 63) Step Action 1. Turn the key off. 2. Disconnect EHCU connector 3. Measure the RL speed sensor resistance between EHCU connector terminals 22 and 23. Go to Step 2 Go to Step 3 Is the resistance between 1.3k and 1.9k ohms? Is there play in the sensor/sensor rotor?

  • Page 637: Chart B-23 Rr Speed Sensor Short Circuit (Dtc 64)

    BRAKE CONTROL SYSTEM 5A–39 Chart B-23 RR Speed Sensor Short Circuit (DTC 64) Step Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the RR speed sensor resistance between EHCU connector terminals 2 and 3. Go to Step 2 Go to Step 3 Is the resistance between 1.3k and 1.9k ohms? Is there play in the sensor/sensor rotor?

  • Page 638: Chart B-24 Sensor Signal Input Abnormality (Dtc 65)

    5A–40 BRAKE CONTROL SYSTEM Chart B-24 Sensor Signal Input Abnormality (DTC 65) Step Action Using TECH 2? Go to Step 2 Go to Step 3 1. Connect TECH 2. 2. Select Snap shot manual trigger. Go to Step 3 3. With wheel speed data displayed, run the vehicle when speed All the sensors has arrived at 30 km/h (18 mph).

  • Page 639: Chart C-1-1 Fl Sensor Output Inspection Procedure

    BRAKE CONTROL SYSTEM 5A–41 Unit Inspection Procedure “DIAGNOSIS BY ‘ABS’ WARNING LIGHT ILLUMINA- TION PATTERN” : This section describes the following inspection proce- dures referred to during “SYMPTOM DIAGNOSIS” and without TECH 2 with TECH 2 Wheel Speed Sensor Output Inspection Chart C-1-1 to C-1-4 Chart TC-1 Transmission SW Inspection...

  • Page 640: Chart C-1-2 Fr Sensor Output Inspection Procedure

    5A–42 BRAKE CONTROL SYSTEM Chart C-1-2 FR Sensor Output Inspection Procedure Step Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning FR wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 4 and 5 under 200 Go to Step 2...

  • Page 641: Chart C-1-4 Rr Sensor Output Inspection Procedure

    BRAKE CONTROL SYSTEM 5A–43 Chart C-1-4 RR Sensor Output Inspection Procedure Step Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning RR wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 2 and 3 under 200 Go to Step 2...

  • Page 642: Chart C-2 Transmission Input Inspection Procedure

    5A–44 BRAKE CONTROL SYSTEM Chart C-2 Transmission Input Inspection Procedure Step Action 1. Turn the key off. Shorted switch 2. Disconnect EHCU connector. harness. Repair switch or Is there continuity between EHCU connector terminals 6 and 15 harness. (Gear position-P(A/T), N(M/T))? Go to Step 2 Go to Step 6 Is the vehicle an A/T model?

  • Page 643: Chart Tc-2 Transmission Input Inspection Procedure (Use Tech 2)

    BRAKE CONTROL SYSTEM 5A–45 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2) Step Action 1. Connect TECH 2. 2. Select Data List. Is this vehicle an A/T model ? Go to Step 2 Go to Step 4 Is “Off–Road Switch(Transmission Input): Active” when the shift lever is the L and R? Go to Step 3 Go to Step 6...

  • Page 644: Special Tools

    5A–46 BRAKE CONTROL SYSTEM Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–35616 Connector test adapter J–39200 High impedance multimeter 7000086–ISU Tech 2 Set (1) PCMCIA Card (2) SAE 16/19 Adapter (3) DLC Cable (4) Tech 2...
  • Page 645 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.

  • Page 646: Electronic Hydraulic Control Unit

    ANTI–LOCK BRAKE SYSTEM 5B–2 Electronic Hydraulic Control Unit Electronic Hydraulic Control Unit and Associated Parts 350RW013 Legend (3) Bolts (1) Connector (4) Nut (2) Hydraulic Unit ASM (5) Bolt Removal Installation To install, follow the removal steps in the reverse order, 1.

  • Page 647: G-Sensor

    ANTI–LOCK BRAKE SYSTEM 5B–3 G-Sensor Removal Installation 1. Install G-sensor assembly (3). D Care should be taken so that the G-sensor is not installed in the wrong direction. 2. Install G-sensor assembly fixing bolt (2). D Tighten the fixing bolt to the specified torque. Torque : 10 N·m (87 lb in) 3.

  • Page 648: Front Wheel Speed Sensor

    ANTI–LOCK BRAKE SYSTEM 5B–4 Front Wheel Speed Sensor Front Wheel Speed Sensor and Associated Parts 350RW012 Legend (3) Sensor Cable Fixing Bolt (Lower side) (1) Speed Sensor Connector (4) Sensor Cable Fixing Bolt (Sensor side) (2) Sensor Cable Fixing Bolt (Upper side) (5) Speed Sensor Removal 1.
  • Page 649 ANTI–LOCK BRAKE SYSTEM 5B–5 Inspection and Repair NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 1. Check the speed sensor pole piece for presence of 5. Install speed sensor connector. foreign materials;...

  • Page 650: Inspection And Repair

    ANTI–LOCK BRAKE SYSTEM 5B–6 Rear Wheel Speed Sensor Rear Wheel Speed Sensor and Associated Parts 350RW008 Legend (3) Clip (11 pieces) (1) Speed Sensor Connector (4) Speed Sensor (2) Sensor Cable Fixing Bolt (5) Sensor Fixing Bolt Removal 2. Check the pole piece for damage, and replace the speed sensor if necessary.
  • Page 651 SECTION POWER ASSISTED BRAKE SYSTEM 5C–1 TROOPER BRAKES POWER-ASSISTED BRAKE SYSTEM CONTENTS Service Precaution ..... . 5C–2 Master Cylinder Assembly and Associated Parts .

  • Page 652: Service Precaution

    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.
  • Page 653 POWER ASSISTED BRAKE SYSTEM 5C–3 CAUTION: 3. The torque values specified dry, un-lubricated fasteners. 1. The master cylinder is not repairable. If found defective, it must be replaced as a complete 4. Perform service operations on a clean bench free assembly.
  • Page 654 5C–4 POWER ASSISTED BRAKE SYSTEM 5. The torque values specified are for dry, unlubricated 6. Perform the service operation on a clean bench free fasteners. from all mineral oil materials. Operation Front Disc Brake A05RW001 Rear Disc Brake A05RW002 Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force.

  • Page 655: Diagnosis

    POWER ASSISTED BRAKE SYSTEM 5C–5 Diagnosis 3. Wheel Alignment: Misalignment of the wheels, particularly in regard to excessive camber and caster, Road Testing The Brakes will cause the brakes to pull to one side. Brake Test Brake Fluid Leaks Brakes should be tested on a dry, clean, reasonably With engine running at idle and the transmission in smooth and level roadway.

  • Page 656: General Diagnosis

    5C–6 POWER ASSISTED BRAKE SYSTEM General Diagnosis Condition Possible cause Correction Brake Pull Tire inflation pressure is unequal. Adjust Front wheel alignment is incorrect. Adjust Unmatched tires on same axle. Tires with approx. the same amount of tread should be used on the same axle.
  • Page 657 POWER ASSISTED BRAKE SYSTEM 5C–7 Condition Possible cause Correction Excessive Brake Pedal Travel Air in hydraulic circuit. Bleed the hydraulic circuit. Level of brake fluid in the reservoir Replenish brake fluid reservoir to too low. specified level and bleed hydraulic circuit as necessary.
  • Page 658 5C–8 POWER ASSISTED BRAKE SYSTEM Condition Possible cause Correction Poor Brake Action Master cylinder faulty. Correct or replace. Vacuum booster faulty. Correct or replace. Level of brake fluid in reservoir too Replenish and bleed. low. Air in hydraulic circuit. Bleed Disc brake caliper faulty.

  • Page 659: Hydraulic Brakes

    POWER ASSISTED BRAKE SYSTEM 5C–9 Hydraulic Brakes Filling Master Cylinder Reservoir cylinder and brakes, then the brake system served by the disconnected pipe must be bled. CAUTION: Use only specified brake fluid. Do not 1. For 4–Wheel Antilock Brake System (ABS) equipped use any fluid which contains a petroleum base.

  • Page 660: Flushing Brake Hydraulic System

    5C–10 POWER ASSISTED BRAKE SYSTEM 16. Repeat steps 13 through 15 until no air comes out of 27. Depress the brake pedal to check if you feel the port when the brake pipe is loosened “sponginess” after the air has been removed from all wheel cylinders and calipers.

  • Page 661: Front / Rear Caliper Brake Hose

    POWER ASSISTED BRAKE SYSTEM 5C–11 Front / Rear Caliper Brake Hose Front / Rear Caliper Brake Hose and Installation Associated Parts To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque Torque: 16 N·m (12 lb ft) 2.

  • Page 662: Rear Axle Brake Hose

    5C–12 POWER ASSISTED BRAKE SYSTEM Rear Axle Brake Hose Rear Axle Brake Hose and Associated Installation Parts To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque Torque: 16 N·m (12 lb ft) 2.

  • Page 663: Brake Pipe

    POWER ASSISTED BRAKE SYSTEM 5C–13 Brake Pipe Removal Installation To install, follow the removal steps in the reverse order, 1. Raise the vehicle and support it with suitable safety noting the following points: stands. 1. Tighten the brake pipes to the specified torque. 2.

  • Page 664: P & B (Proportioning And Bypass) Valve

    5C–14 POWER ASSISTED BRAKE SYSTEM P & B (Proportioning and Bypass) Valve P & B (Proportioning and Bypass) Removal Valve Sectional View 1. The P&B valve is not repairable and must be replaced as a complete assembly. Care must be taken to prevent brake fluid from contacting any painted surface.

  • Page 665: Main Data And Specifications

    POWER ASSISTED BRAKE SYSTEM 5C–15 Main Data and Specifications Torque Specifications E05RW001...

  • Page 666: Brake Pedal

    5C–16 POWER ASSISTED BRAKE SYSTEM Brake Pedal Checking Pedal Height The push rod serves as the brake pedal stopper when the pedal is fully released. Brake pedal height adjustment should be performed as follows: Adjust Brake Pedal 310RY00001 NOTE: While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal.

  • Page 667: Brake Pedal And Associated Parts

    POWER ASSISTED BRAKE SYSTEM 5C–17 Brake Pedal and Associated Parts 310RY00002 Legend (7) Front Console Assembly (1) Nut (8) Instrument Panel Driver Lower Cover (2) Stoplight Switch Connector (9) Return Spring (3) Fulcrum Pin (10) Brake Pedal (4) Driver Knee Bolster Assembly (11) Snap Pin (5) Lower Cluster Assembly (12) Pin...

  • Page 668: Stoplight Switch

    5C–18 POWER ASSISTED BRAKE SYSTEM 11. Install lower cluster assembly. 13. Install shift knob. 12. Install front console assembly. Stoplight Switch Removal 1. Remove shift knob. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove instrument panel driver lower cover. 5.

  • Page 669: Main Data And Specifications

    POWER ASSISTED BRAKE SYSTEM 5C–19 Main Data and Specifications General Specifications Pedal free play 6–10 mm (0.23 –0.39 in) Pedal Height 208–218 mm (819–8.58 in) Torque Specifications E05RW002...

  • Page 670: Fluid Reservoir Tank

    5C–20 POWER ASSISTED BRAKE SYSTEM Fluid Reservoir Tank Fluid Reservoir Tank and Associated Parts 330RW003 Legend (3) O–ring (1) Fluid Reservoir (4) Retainer (2) Electrical Connector Removal Installation To install, follow the removal steps in the reverse order, NOTE: Before removing the fluid reservoir, remove the noting the following points: brake fluid from the fluid reservoir.

  • Page 671: Master Cylinder Assembly

    POWER ASSISTED BRAKE SYSTEM 5C–21 Master Cylinder Assembly Master Cylinder Assembly and Associated Parts 330RW006 Legend (4) P&B Valve and Bracket (1) Electrical Connector (5) Brake Pipes (2) Master Cylinder (6) Spacer and 2 gaskets (3) 2 attaching Nuts Removal 4.

  • Page 672: Installation

    5C–22 POWER ASSISTED BRAKE SYSTEM D O–ring There should be a pressure increase of 0.5 kg/cm@ or more. Functional Inspection of Master Cylinder Piston Push the primary piston (1) with your fingers to check that it travels smoothly. If the motion is questionable, replace the master cylinder as a complete assembly.

  • Page 673: Main Data And Specifications

    POWER ASSISTED BRAKE SYSTEM 5C–23 5. Install brake pipes and tighten the brake pipe to the specified torque. Master cylinder side Torque: 12 N·m (104 lb in) Others Torque: 16 N·m (12 lb ft) 6. Connect electrical connector. Main Data and Specifications General Specifications Type Dual–circuit...

  • Page 674: Special Tools

    5C–24 POWER ASSISTED BRAKE SYSTEM Special Tools TOOL NO. ILLUSTRATION TOOL NAME J-39242 Primary Piston Holder (including master cylinder attachment and master cylinder plug J-24460-01 Radiator Cap Tester...

  • Page 675: Vacuum Booster Assembly

    POWER ASSISTED BRAKE SYSTEM 5C–25 Vacuum Booster Assembly Vacuum Booster Assembly and Associated Parts 331RW001 Legend (4) Master Cylinder (1) Pin (5) Vacuum Booster (2) Vacuum Booster Fixing Nut (6) Snap Pin (3) Vacuum Hose Removal Outside surface of the piston is the surface on which seals are to slide.

  • Page 676: Installation

    5C–26 POWER ASSISTED BRAKE SYSTEM 3. Air should not pass from the engine (1) to the vacuum 3. Set push rod gauge J–39216 on vacuum booster, and booster (3). If it does, the check valve is inoperative apply negative pressure by means of vacuum pump and the vacuum hose built check valve must be J–23738–A so that the pressure in the vacuum replaced.
  • Page 677 POWER ASSISTED BRAKE SYSTEM 5C–27 5. If dimension (4) is out of the standard range, adjust push rod using the Push Rod Support J–39241. 331RW003 6. Mount plate and seal assembly in vacuum booster front shell. Then install the retainer. 7.

  • Page 678: Exterior Components

    5C–28 POWER ASSISTED BRAKE SYSTEM Exterior Components Exterior Components and Associated Parts 331RW004 Legend (6) Filter (1) Yoke Clevis (7) 2 Gaskets and Spacer (2) Lock Nut (8) Vacuum Booster (3) Retaining Clip (9) Retainer (4) Valve Body Guard (10) Plate and Seal Assembly (5) Silencer (11) Master Cylinder Removal...

  • Page 679: Inspection And Repair

    POWER ASSISTED BRAKE SYSTEM 5C–29 11. Remove plate and seal assembly. 2. Install retainer. 3. Install 2 gaskets and spacer. Inspection and Repair 4. Install filter. 5. Install silencer. Visual Check 6. Install valve body guard. Make necessary parts replacement if cuts, nicks, 7.

  • Page 680: Main Data And Specifications

    5C–30 POWER ASSISTED BRAKE SYSTEM Main Data and Specifications General Specifications Vacuum booster diaphragm diameter (Front) 205 mm (8.07 in) Vacuum booster diaphragm diameter (Rear) 230 mm (9.06 in) Push rod stroke More than 32.0 mm (1.26 in) Plunger diameter 10.25 mm (0.40 in) Push rod diameter 27.4 mm (1.08 in)

  • Page 681: Special Tools

    POWER ASSISTED BRAKE SYSTEM 5C–31 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J-39216 Push Rod Gauge J-23738-A Vacuum Pump J-39241 Push Rod Support...

  • Page 682: Front Disc Brake Pads

    5C–32 POWER ASSISTED BRAKE SYSTEM Front Disc Brake Pads Front Disc Brake Pads Inspection Check the outer pad by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements.

  • Page 683: Removal

    POWER ASSISTED BRAKE SYSTEM 5C–33 Removal NOTE: If a squealing noise occurs from the front brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced. D Draw out two–thirds of the brake fluid from the reservoir.
  • Page 684 5C–34 POWER ASSISTED BRAKE SYSTEM 302RW006 302RW007 3. Install caliper assembly, use adjustable pliers to 5. Install wheel and tire assembly, refer to “Wheels and bottom the piston into the caliper bore. Tires System” in Section 3E. Be careful do not damage the piston boot and do not 6.

  • Page 685: Front Disc Brake Rotor

    POWER ASSISTED BRAKE SYSTEM 5C–35 Front Disc Brake Rotor Inspection The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. In the manufacturing of the brake rotor, all the tolerances Maximum runout: 0.010 mm (0.0004 in) regarding surface finish, parallelism and lateral runout are held very closely.
  • Page 686 5C–36 POWER ASSISTED BRAKE SYSTEM After refinishing, replace any rotor that does not meet the minimum thickness of 24.97 mm (0.983 in). Do not use a brake rotor that will not meet the specification. Minimum wear dimension: 24.60 mm (0.969 in) Refinish dimension: 24.97 mm (0.983 in) 411RW003...

  • Page 687: Front Disc Brake Caliper Assembly

    POWER ASSISTED BRAKE SYSTEM 5C–37 Front Disc Brake Caliper Assembly Front Disc Brake Caliper Assembly and Associated Parts 302RW008 Legend (4) Caliper Assembly (1) Guide Bolt (5) Clip (2) Brake Flexible Hose (6) Support Bracket with Pad Assembly (3) Lock Bolt (7) Pad Assembly Removal 1.

  • Page 688: Installation

    5C–38 POWER ASSISTED BRAKE SYSTEM 4. Since the brake fluid flows out from the connecting 2. Install pad assembly with shim and apply special coupler, place a drain pan under the vehicle. grease (approximately 0.2 g) to both contacting surfaces of the inner shims (6). Wipe off extruded 5.
  • Page 689 POWER ASSISTED BRAKE SYSTEM 5C–39 5. Install lock bolt (9) and guide bolt (8) and tighten the bolt to the specified torque. Torque: 74 N·m (54 lb ft) 302RW013 6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity then tighten the I–bolt (10) to the specified torque.

  • Page 690: Front Disc Brake Caliper

    5C–40 POWER ASSISTED BRAKE SYSTEM Front Disc Brake Caliper Front Disc Brake Caliper Disassembled View 302RW015 Legend (5) Dust Boot: Guide Bolt and Lock Bolt (1) Guide Bolt (6) Piston Seal (2) Lock Bolt (7) Piston (3) Bleeder with Cap (8) Dust Boot: Piston (4) Caliper Body (9) Dust Boot Ring...

  • Page 691: Inspection And Repair

    POWER ASSISTED BRAKE SYSTEM 5C–41 5. Insert a block of wood into the caliper and force out Reassembly the piston by blowing compressed air into the caliper 1. Install caliper body. at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. 2.
  • Page 692 5C–42 POWER ASSISTED BRAKE SYSTEM 6. Install dust boot ring and apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot. 302RS020 7.

  • Page 693: Main Data And Specifications

    POWER ASSISTED BRAKE SYSTEM 5C–43 Main Data and Specifications General Specifications Type Floating, pin slide Pad dimension 55 cm@ (8.52 in@) Adjusting method Self–adjusting Piston diameter 60.33 mm (2.38 in) Disc type Ventilated Disc thickness 26 mm (1.02 in) Disc effective diameter 222 mm (8.74 in) Torque Specifications E05RW004...

  • Page 694: Rear Disc Brake Pads

    5C–44 POWER ASSISTED BRAKE SYSTEM Rear Disc Brake Pads Brake Pads Inspection Check the outer pads by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements.

  • Page 695: Removal

    POWER ASSISTED BRAKE SYSTEM 5C–45 Removal NOTE: If a squealing noise occurs from the rear brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced. D Draw out two–thirds of the brake fluid from the reservoir.
  • Page 696 5C–46 POWER ASSISTED BRAKE SYSTEM 306RW005 306RW006 3. Install caliper assembly, use adjustable pliers to bottom the piston into the caliper bore. Be careful not to damage the piston dust boot and do not damage the flexible hose by twisting or pulling it. 302RS008 4.

  • Page 697: Rear Disc Brake Rotor

    POWER ASSISTED BRAKE SYSTEM 5C–47 Rear Disc Brake Rotor Inspection The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. In the manufacturing of the brake rotor, all the tolerances Maximum parallelism: 0.001 mm (0.0004 in) regarding surface finish, parallelism and lateral runout are held very closely.

  • Page 698: Rear Drum (In Disc) Inside Diameter Check 5C-48

    5C–48 POWER ASSISTED BRAKE SYSTEM After refinishing, replace any rotor that does not meet the minimum thickness of 16.97 mm (0.668 in). Do not use a brake rotor that will not meet the specification. Minimum wear dimension: 16.6 mm (0.654 in) Refinish dimension: 16.97 mm (0.668 in) 420RW002 Rear Drum (In Disc) Inside Diameter...

  • Page 699: Rear Disc Brake Caliper Assembly

    POWER ASSISTED BRAKE SYSTEM 5C–49 Rear Disc Brake Caliper Assembly Rear Disc Brake Caliper Assembly and Associated Parts 306RW007 Legend (4) Support Bracket (1) Brake Flexible Hose (5) Guide Bolt (2) Clip (6) Pad Assembly with Shim (3) Lock Bolt (7) Caliper Assembly Removal 4.

  • Page 700: Installation

    5C–50 POWER ASSISTED BRAKE SYSTEM 10. Remove clip. 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 103 N·m (76 lb ft) Installation 1. Install clip (4). 306RW012 4. Install caliper assembly. 306RW010 5. Install lock bolt and guide bolt (8) and tighten the bolt 2.
  • Page 701 POWER ASSISTED BRAKE SYSTEM 5C–51 6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity then tighten the I–bolt (9) to the specified torque. Torque: 35 N·m (26 lb ft) 302RW017 7.

  • Page 702: Rear Disc Brake Caliper

    5C–52 POWER ASSISTED BRAKE SYSTEM Rear Disc Brake Caliper Rear Disc Brake Caliper Disassembled View 306RW014 Legend (5) Piston Seal (1) Guide Bolt (6) Piston (2) Lock Bolt (7) Dust Boot: Piston (3) Bleeder with Cap (8) Dust Boot Ring (4) Caliper Body (9) Dust Boot: Guide Bolt and Lock Bolt Disassembly...

  • Page 703: Inspection And Repair

    POWER ASSISTED BRAKE SYSTEM 5C–53 5. Insert a block of wood into the caliper and force out Reassembly the piston by blowing compressed air into the caliper 1. Install caliper body. at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. 2.
  • Page 704 5C–54 POWER ASSISTED BRAKE SYSTEM 6. Install dust boot ring and apply special grease (approximately 1g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot. 302RS020 7. Install guide bolt and lock bolt dust boot. 8.

  • Page 705: Main Data And Specifications

    POWER ASSISTED BRAKE SYSTEM 5C–55 Main Data and Specifications General Specifications Type Floating, pin slide Pad dimension 33 cm@ (5.11 in@) Adjusting method Self–adjusting Piston diameter 41.3 mm (1.63 in) Disc type Ventilated Disc thickness 18 mm (0.71 in) Disc effective diameter 269.2 mm (10.60 in) Torque Specifications E05RW005...

  • Page 706: Parking Brake System

    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.
  • Page 707 5D–2 PARKING BRAKE Operation C05RW003 Legend (6) Parking Cable Guide (1) Strut (7) Primary Shoe (2) Fulcrum B (8) Parking Brake Cable Guide (9) Adjusting Hole Plug (3) Parking Lever (4) Secondary Shoe (10) Adjusting Screw Notch (5) Adjusting Screw Notch (11) Shoe Expanding Direction When pulled in the direction “A”, the parking lever presses the secondary shoe against the brake drum using the...

  • Page 708: Removal

    PARKING BRAKE 5D–3 Parking Brake Lever and Front Cable Parking Brake Lever, Front Cable and Associated Parts 311RW001 Legend (4) Equalizer (1) Parking Brake Lever (5) Parking Brake Front Cable (2) Bolt (6) Switch Connector (3) Adjusting Nut Removal 1. Remove adjusting nut (3). 2.

  • Page 709: Installation

    5D–4 PARKING BRAKE 3. Remove center console. (Refer to Section 10 “Body”.) 4. Remove bolts. 5. Disconnect switch connector. 6. Remove parking brake lever. 7. Remove parking brake front cable. Installation 1. Install parking brake front cable. 2. Install parking brake lever and apply grease (BESCO L–2 or equivalent) to front cable contact point.

  • Page 710: Parking Brake Rear Cable

    PARKING BRAKE 5D–5 Parking Brake Rear Cable Parking Brake Rear Cable and Associated Parts 311RW003 Legend (8) Caliper Assembly (1) Adjust Nut (9) Rotor (Drum) (2) Back Plate (10) Rear Wheels (3) Bolt (11) Cable Fixing Bolt (4) Holding Spring (12) Clip (5) Return Spring;...

  • Page 711: Installation

    5D–6 PARKING BRAKE 6. Remove bolt. 7. Remove back plate. 8. Remove clip (frame side). 9. Remove clip (suspension side). 10. Remove holding spring. 11. Remove return spring; upper. 12. Remove return spring; lower. 13. Remove the brake shoe assembly. Then remove the parking brake cable from the parking brake lever (1).

  • Page 712: Inspection And Repair

    PARKING BRAKE 5D–7 13. Install caliper assembly. 2. Adjustment of parking brake cable 14. Install rear wheels. a. Turn the equalizer nut so that the parking brake lever travels 6 or 7 notches when pulled up with a 15. Install adjusting nut and apply grease (BESCO L–2 or force of 30 kg (66 lb).

  • Page 713: Main Data And Specifications

    5D–8 PARKING BRAKE Main Data and Specifications General Specifications Rear parking brake Type Duo–servo Lining Dimension 121.2 cm@ (18.79 in@) Adjusting Method Manual adjusting Rotor (Drum) Inside Diameter 210 mm (8.27 in) Parking Brake Lever Stroke 6–7 notches When pulled with a force of 30 kg (66 lb) Torque Specifications E05RW006...

  • Page 714: Engine Mechanical

    SECTION ENGINE MECHANICAL 6A–1 TROOPER ENGINE CONTENTS Engine Mechanical ..... . Driveability and Emissions ....Engine Cooling .

  • Page 715: Service Precaution

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 716: General Description

    ENGINE MECHANICAL 6A–3 General Description Cylinder Head The cylinder head, made of aluminum alloy casting Engine Cleanliness And Care employs a pent–roof type combustion chamber with a An automobile engine is a combination of many spark plug in the center. The intake and exhaust valves machined, honed, polished and lapped surfaces with are placed in V–type design.

  • Page 717: Engine Diagnosis

    6A–4 ENGINE MECHANICAL Engine Diagnosis Hard Starting 1. Starting Motor Does Not Turn Over Troubleshooting Procedure Turn on headlights and starter switch. Condition Possible cause Correction Headlights Battery run down or under charged Recharge or replace battery considerably considerably Terminals poorly connected Clean battery posts and terminals and connect properly Starting motor coil circuit shorted...
  • Page 718 ENGINE MECHANICAL 6A–5 4. Engine Lacks Compression Condition Possible cause Correction Engine lacks compression Spark plug loosely fitted or spark Tighten to specified torque or replace plug gasket defective gasket Valve timing incorrect Adjust Cylinder head gasket defective Replace gasket Valve incorrectly seated Lap valve Valve stem seized...
  • Page 719 6A–6 ENGINE MECHANICAL Rough Engine Idling or Engine Stalling Condition Possible cause Correction Trouble in fuel injection system Throttle shutting off incomplete Correct or replace Throttle position sensor circuit open Correct or replace or shorted Fuel injector circuits open or shorted Correct or replace Fuel injectors damaged Replace...
  • Page 720 ENGINE MECHANICAL 6A–7 Rough Engine Running Condition Possible cause Correction Engine misfires periodically Ignition coil layer shorted Replace Spark plugs fouling Clean or install hotter type plug Spark plug(s) insulator nose leaking Replace Fuel injector(s) defective Replace Powertrain control module faulty Replace Engine knocks periodically Spark plugs running too hot...
  • Page 721 6A–8 ENGINE MECHANICAL Hesitation Condition Possible cause Correction Hesitation on acceleration Throttle Position Sensor adjustment Replace throttle valve assembly incorrect Throttle Position Sensor circuit open Correct or replace or shorted Mass Airflow Sensor circuit open or Correct or replace poor connections Mass Airflow Sensor defective Replace Manifold Absolute Pressure (MAP)
  • Page 722 ENGINE MECHANICAL 6A–9 Condition Possible cause Correction Hesitation at high speeds Powertrain Control Module defective Replace Throttle Position Sensor cable Correct or replace broken or poor connections Throttle Position Sensor defective Replace Engine Coolant Temperature Sensor Correct or replace circuit open or shorted Engine Coolant Temperature Sensor Replace defective...
  • Page 723 6A–10 ENGINE MECHANICAL Engine Lacks Power Condition Possible cause Correction Trouble in fuel system Fuel Pressure Control Valve not Replace working normally Fuel injector clogged Clean or replace Fuel pipe clogged Clean Fuel filter clogged or fouled Replace Fuel pump drive circuit not working Correct or replace normally Fuel tank not sufficiently breathing...
  • Page 724 ENGINE MECHANICAL 6A–11 Condition Possible cause Correction Engine overheating Level of Engine Coolant too low Replenish Fan clutch defective Replace Incorrect fan installed Replace Thermostat defective Replace Engine Coolant pump defective Correct or replace Radiator clogged Clean or replace Radiator filler cap defective Replace Level of oil in engine crankcase too Change or replenish...
  • Page 725 6A–12 ENGINE MECHANICAL Troubleshooting Procedure Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out. Condition Possible cause Correction Noise from connecting rods or from Bearing or crankshaft pin worn Replace connecting rod bearings...
  • Page 726 ENGINE MECHANICAL 6A–13 Troubleshooting Procedure The slapping sound stops when spark plug on bad cylin- der is shorted out. Condition Possible cause Correction Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension pulley or replace timing belt Tensioner bearing defective Replace Timing belt defective...
  • Page 727 6A–14 ENGINE MECHANICAL Abnormal Combustion Condition Possible cause Correction Trouble in fuel system Fuel pressure control valve defective Replace Fuel filter clogged Replace Fuel pump clogged Clean or replace Fuel tank or fuel pipe clogged Clean or replace Fuel injector clogged Clean or replace Fuel pump relay defective Replace...
  • Page 728 ENGINE MECHANICAL 6A–15 Condition Possible cause Correction Trouble in cylinder head parts Carbon deposits in combustion Remove carbon chamber Carbon deposit on valve, valve seat Remove carbon and valve guide...
  • Page 729 6A–16 ENGINE MECHANICAL Engine Oil Consumption Excessive Condition Possible cause Correction Oil leaking Oil pan drain plug loose Retighten or replace gasket Crankcase fixing bolts loosened Retighten Oil pan setting bolts loosened Retighten Oil pan gasket broken Replace gasket Front cover retaining bolts loose or Retighten or replace gasket gasket broken Head cover fixing...
  • Page 730 ENGINE MECHANICAL 6A–17 Fuel Consumption Excessive Condition Possible cause Correction Trouble in fuel system Mixture too rich or too lean due to Refer to “Abnormal Combustion” trouble in fuel injection system Fuel cut function does not work Refer to “Abnormal Combustion” Trouble in ignition system Misfiring or abnormal combustion Refer to “Hard Start”...
  • Page 731 6A–18 ENGINE MECHANICAL Malfunction Indicator Lamp The instrument panel “CHECK ENGINE” Malfunction In- dicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Condition Possible cause Correction “CHECK ENGINE” MIL does not Bulb defective Replace illuminate at the starting of engine...

  • Page 732: Cylinder Head Cover Lh

    ENGINE MECHANICAL 6A–19 Cylinder Head Cover LH Removal 5. Ignition coil connector and ignition coil. D Disconnect the three connectors from the ignition 1. Disconnect battery ground cable. coils. 2. Remove engine cover from the dowels on the D Remove harness bracket bolt on cylinder head common chamber.

  • Page 733: Installation

    6A–20 ENGINE MECHANICAL Installation 1. Install cylinder head cover. D Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. D Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bearing cap on front and rear sides.

  • Page 734: Cylinder Head Cover Rh

    ENGINE MECHANICAL 6A–21 Cylinder Head Cover RH Removal Installation 1. Disconnect battery ground cable. 1. Install cylinder head cover. D Clean the sealing surface of cylinder head and 2. Remove engine cover from the dowele on the common chamber. cylinder head cover to remove oil and sealing materials completely.

  • Page 735: Common Chamber

    6A–22 ENGINE MECHANICAL Common Chamber Removal 1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 025RY002 Legend (1) Common Chamber (2) Throttle Valve Assembly (3) Bolt 013RY00001 Legend (1) Positive Crankcase Ventilation Hose Connector Installation (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly 1.
  • Page 736 ENGINE MECHANICAL 6A–23 9. Connect the ion sensing module connectors as shown in the illustration. 060RY00111 Legend (1) Green Connector (2) Blue Connector (3) Identification Mark (6VE1 Engine Only) 10. Install air cleaner duct assembly. 013RY00001 Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Mass Air Flow Sensor...

  • Page 737: Exhaust Manifold Lh

    6A–24 ENGINE MECHANICAL Exhaust Manifold LH Removal Installation 1. Disconnect battery ground cable. 1. Install exhaust manifold and gasket and tighten exhaust manifold fixing nuts to the specified torque 2. Remove transfer case skid plate. with new nuts. 3. Remove 3rd crossmember. Torque: 52 N·m (38 lb ft) 4.

  • Page 738: Exhaust Manifold Rh

    ENGINE MECHANICAL 6A–25 Exhaust Manifold RH Removal 035RX016 Legend (4) Front Propeller Shaft (1) Exhaust Front Pipe RH (5) Transfer Case Skid Plate (2) O Sensors (6) 3rd Crossmember (3) Torsion Bar 1. Disconnect battery ground cable. Torque : 44 N·m (33 lb ft) 2.

  • Page 739: Crankshaft Pulley

    6A–26 ENGINE MECHANICAL Crankshaft Pulley Removal 4. Move serpentine belt tensioner to loose side using wrench then remove serpentine belt. 1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 850RW001 Legend (1) Crankshaft Pulley 013RY00001 Legend (2) Cooling Fan Pulley (1) Positive Crankcase Ventilation Hose Connector (3) Tensioner (2) Intake Air Temperature Sensor...

  • Page 740: Timing Belt

    ENGINE MECHANICAL 6A–27 Timing Belt Removal 11. Remove right side timing belt cover then left side timing belt cover. 1. Disconnect battery ground cable. 12. Remove lower timing belt cover 2. Remove air cleaner assembly. 13. Remove pusher. 3. Remove radiator upper fan shroud from radiator. CAUTION: The pusher prevents air from entering 4.

  • Page 741: Installation

    6A–28 ENGINE MECHANICAL Installation 1. Install timing belt. 1. Align groove of crankshaft timing pulley with mark NOTE: For correct belt installation, the letter on the belt on oil pump. must be able to be read as viewed from the front of the Align the mark on the crankshaft timing pulley vehicle.
  • Page 742 ENGINE MECHANICAL 6A–29 2. Align the marks on the camshaft drive gear NOTE: It is recommended for easy installation that the pulleys with the corresponding alignment marks belt be secured with a double clip after it is installed to on the cylinder head covers. each pulley.
  • Page 743 6A–30 ENGINE MECHANICAL 014RW011 020RW003 Legend Legend (1) Up Side (1) Timing Belt Cover (2) Down Side (2) Rubber Bushing (3) Direction for Installation (3) Sealing Rubber (4) Locking Pin (4) Cylinder Body 4. Install crankshaft pulley using J-8614-01, hold the 3.
  • Page 744 ENGINE MECHANICAL 6A–31 8. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position. 850RW001 Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Auto Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 9.

  • Page 745: Camshaft

    6A–32 ENGINE MECHANICAL Camshaft Removal 1. Disconnect battery ground cable. 2. Remove crankshaft pulley. D Refer to removal procedure for Crankshaft Pulley in this manual. 3. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual. 4.
  • Page 746 ENGINE MECHANICAL 6A–33 014RW023 014RW041 4. Install camshaft assembly and camshaft bearing Legend caps, tighten twenty bolts on one side bank to the (1) Right Bank Camshaft Drive Gear specified torque. (2) Left Bank Camshaft Drive Gear 1. Apply engine oil to camshaft journal and bearing (3) Timing Mark on Drive Gear surface of camshaft bearing cap.
  • Page 747 6A–34 ENGINE MECHANICAL 014RW024 Legend (3) Alignment Mark on Camshaft Drive Gear (1) Right Bank (4) Alignment Mark on Camshaft (2) Left Bank (5) Alignment Mark on Retainer 3. Tighten twenty bolts on numerical order an one 5. Install cylinder head cover RH. side bank as shown in the illustration.

  • Page 748: Cylinder Head

    ENGINE MECHANICAL 6A–35 Cylinder Head Removal Installation 1. Remove engine hood. 1. Install cylinder head assembly to cylinder block. 2. Disconnect battery ground cable. A. Put cylinder head gasket on the cylinder block. 3. Drain radiator coolant. NOTE: There is discrimination mark “R” for right bank 4.
  • Page 749 6A–36 ENGINE MECHANICAL NOTE: Do not reuse cylinder head bolts. Do not apply any lubricant to the cylinder head bolts. Torque : Temporary : 29 N·m (21 lb ft) Final : 64 N·m (47 lb ft) 014RW029 2. Install common chamber. D Refer to installation procedure for Common Chamber in this manual.

  • Page 750: Valve Stem Oil Controller , Valve Spring And Valve Guide

    ENGINE MECHANICAL 6A–37 Valve Stem Oil Controller , Valve Spring and Valve Guide Removal Installation 1. Disconnect battery ground cable. 1. Install valve guide using J–42899 valve guide installer. 2. Drain engine oil. 2. Install oil controller using J–38537 oil controller D Drain engine coolant.

  • Page 751: Piston, Piston Ring And Connecting Rod

    6A–38 ENGINE MECHANICAL Piston, Piston Ring and Connecting Rod Removal F06RW011 Legend (4) Oil Strainer (1) Cylinder Head (5) Oil Gallery (2) Crankcase with Oil Pan (6) Piston with Connecting Rod Assembly (3) Oil Pipe 1. Remove cylinder head assembly. 2.

  • Page 752: Installation

    ENGINE MECHANICAL 6A–39 3. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring. 015RW003 Legend (1) Piston Front Mark 050RW002 (2) Piston Grade Legend (3) Connecting Rod Front Mark (1) Oil Pump (2) Oil Strainer 2. Install oil gallery and tighten the bolts in two steps, in (3) Oil Gallery the order shown in illustration.

  • Page 753: Crankshaft And Main Bearings

    6A–40 ENGINE MECHANICAL Crankshaft and Main Bearings Removal F06RY002 Legend (8) Oil Pump Assembly (1) Engine Assembly (9) Cylinder Body Side Bolt (2) Crankshaft Pulley (10) Oil Gallery (3) Timing Belt Cover (11) Flywheel (4) Timing Belt (12) Rear Oil Seal Retainer (5) Crankcase with Oil Pan (13) Connecting Rod Cap (6) Oil Pipe...

  • Page 754: Installation

    ENGINE MECHANICAL 6A–41 6. Remove oil pump assembly. D Refer to removal procedure for Oil Pump in this manual. 7. Remove cylinder body side bolts. 8. Remove oil gallery. 9. Remove flywheel. 10. Remove rear oil seal retainer. D Refer to removal procedure for Rear Oil Seal in this manual.
  • Page 755 6A–42 ENGINE MECHANICAL D The oil seal retainer must be installed within 5 D Tighten fixing bolts to the specified torque. minutes after sealant application before the sealant Torque : 54 N·m (40 lb ft) hardens. 015RS018 015RW002 6. Install oil gallery. Legend D Clean contact surface of oil gallery and main (1) Around Bolt Holes...
  • Page 756 ENGINE MECHANICAL 6A–43 D Apply sealant (TB1207B or equivalent) to the oil 11. Install crankcase. pump mounting surface. D Remove oil on crankcase mounting surface and dry D The oil pump assembly must be installed within 5 the surface. D Properly apply a 4.5 mm (0.7 in) wide bead of minutes after sealant application before the sealant hardens.
  • Page 757 6A–44 ENGINE MECHANICAL D Tighten fixing bolts to the specified torque. Torque : 25 N·m (18 lb ft) 013RW003 013RW002 13. Install timing belt. D Refer to installation procedure for Timing Belt in this manual. 14. Install engine assembly. D Refer to installation procedure for Engine in this manual.

  • Page 758: Rear Oil Seal

    ENGINE MECHANICAL 6A–45 Rear Oil Seal Removal 1. Remove transmission assembly. D Refer to removal procedure for Transmission section in this manual. 2. Remove flywheel. 3. Remove rear oil seal using a seal remover. NOTE: Take care not to damage the crankshaft or oil seal retainer when removing oil seal.

  • Page 759: Engine Assembly

    6A–46 ENGINE MECHANICAL Engine Assembly Removal 035RY00001 1. Disconnect battery ground and positive cable. 23. Move drive belt tensioner to loose side using wrench then remove drive belt. 2. Remove battery. 24. Remove power steering pump fixing bolts, then 3. Make alignment mark on the engine hood and hinges power steering pump.

  • Page 760: Installation

    ENGINE MECHANICAL 6A–47 Installation CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission.
  • Page 761 6A–48 ENGINE MECHANICAL M8 bolts : 22 N·m (16 lb ft) 26. Reconnect throttle position sensor harness connector. M10 bolts : 43 N·m (32 lb ft) 10. Install power steering pump, tighten fixing bolt to the specified torque. Torque : M8 bolts : 22N·m (16 lb ft) M10 bolts : 46 N·m (34 lb ft) 11.

  • Page 762: Cylinder Head

    ENGINE MECHANICAL 6A–49 Cylinder Head Cylinder Head and Associated Parts 011RW008 Legend (8) Camshaft Intake (1) Spark Plug (9) Retainer Fixing Bolt (2) Cylinder Head Bolt (10) Retainer Assembly (3) Camshaft Drive Gear Pulley Fixing Bolt (11) Tappet with Shim (4) Camshaft Drive Gear Pulley (12) Split Collar (5) Camshaft Bearing Cap Fixing Bolt...

  • Page 763: Disassembly

    6A–50 ENGINE MECHANICAL Disassembly Inspection and Repair 1. Cylinder head gasket and mating surfaces for leaks, NOTE: corrosion and blow–by. If the gasket has failed, D During disassembly, be sure that the valve train determine the cause. components are kept together and identified so that –...

  • Page 764: Reassembly

    ENGINE MECHANICAL 6A–51 Reassembly 1. Install Spark plug and tighten all the spark plugs to specified torque. Torque: 18 N·m (13 lb ft) 2. Tighten sub gear setting bolt. 1. Use J–(42686 gear spring lever) to turn sub gear to right direction until the M5 bolt aligns with the hole between camshaft driven gear and sub gear.
  • Page 765 6A–52 ENGINE MECHANICAL 014RW024 Legend (3) Alignment Mark on Camshaft Drive Gear (1) Right Bank (4) Alignment Mark on Camshaft (2) Left Bank (5) Alignment Mark on Retainer 3. Tighten twenty bolts in numerical order on one side bank as shown in the illustration. Torque: 10 N·m (89 lb in) 014RW031 5.

  • Page 766: Valve Spring, Oil Controller, Valve, Valve Guide

    ENGINE MECHANICAL 6A–53 Valve Spring, Oil Controller, Valve, Valve Guide Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts 014RW039 Legend (7) Spring Upper Seat (1) Camshaft Bearing Cap Fixing Bolts (8) Valve Spring (2) Camshaft Assembly Inlet (9) Oil Controller (3) Camshaft Assembly Exhaust (10) Spring Lower Seat (4) Shim...

  • Page 767: Inspection And Repair

    6A–54 ENGINE MECHANICAL 5. Use J–8062 valve spring compressor and J–42898 2. Measure the valve spring squareness with a steel valve spring compressor adapter to remove split square and replace the valve springs if the measured collar. value exceeds the specified limit. Limit : 2 mm (0.0787 in) 014RW042 6.
  • Page 768 ENGINE MECHANICAL 6A–55 1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard : 5.977 mm–5.959 mm (0.2353 in–0.2346 in) Limit : 5.90 mm (0.2323 in)
  • Page 769 6A–56 ENGINE MECHANICAL Limit: 39.47 mm (1.5539 in) 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Exhaust Valve contact surface angle: 45° Standard: 39.30 mm (1.5472 in) Limit: 39.45 mm (1.5531 in) 014RS012 014RW047 Valve Seat Insert Correction...

  • Page 770: Reassembly

    ENGINE MECHANICAL 6A–57 7. Check that the valve seat insert surface is in contact 7. After insertion, use a seat grinder to grind finish the with the entire circumference of the valve. seating face. Carefully note the seating angle, the contact width, and the depression.

  • Page 771: Valve Clearance Adjustments

    6A–58 ENGINE MECHANICAL 5. Install lower valve spring seat, valve spring and upper Valve Clearance Adjustments valve spring seat then put split collars on the upper spring seat, using the J–8062 valve spring NOTE: To adjust valve clearance, apply engine oil to the compressor and J–42898 valve spring compressor cam as well as to the adjusting shim (2) with the cylinder adapter to install the split collars.
  • Page 772 ENGINE MECHANICAL 6A–59 Replacement of Shim Let the cam push down the edge of tappet by using J–42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations below. 014RW084 014RW082 014RW083...

  • Page 773: Camshaft

    6A–60 ENGINE MECHANICAL Camshaft Camshaft and Associated Parts 014RW040 Legend (6) Camshaft Drive Gear Pulley (1) Camshaft Bearing Cap Fixing Bolt (7) Retainer Fixing Bolt (2) Camshaft Bearing Cap (8) Retainer (3) Camshaft Assembly Intake (9) Camshaft Drive Gear (4) Camshaft Assembly Exhaust (10) Oil Seal (5) Pulley Fixing Bolt Disassembly...

  • Page 774: Inspection And Repair

    ENGINE MECHANICAL 6A–61 2. Remove twenty fixing bolts from inlet and exhaust 2. Use a micrometer to measure the diameter and the camshaft bearing cap on one side bank, then uneven wear of the camshaft journals. camshaft bearing cap (2). Replace the camshaft if the diameter or the uneven wear exceeds the specified limit.
  • Page 775 6A–62 ENGINE MECHANICAL 4. Measure the camshaft journal oil clearance. 5. Replace the cylinder head and/or camshaft if the measured oil clearance exceeds the specified limit. 1. Measure the camshaft bearing cap housing inside diameter. 1. Carefully clean the camshaft journal, the camshaft bracket, and the cylinder head.

  • Page 776: Reassembly

    ENGINE MECHANICAL 6A–63 Reassembly 1. Install camshaft drive gear assembly and tighten three bolts to specified torque. Torque: 10 N·m (89 lb in) 2. Tighten sub gear setting bolt. 1. Use J–42686 to turn sub gear to right direction until the M5 bolt hole aligns between camshaft driven gear and sub gear.
  • Page 777 6A–64 ENGINE MECHANICAL 014RW024 Legend (3) Alignment Mark on Camshaft Drive Gear (1) Right Bank (4) Alignment Mark on Camshaft (2) Left Bank (5) Alignment Mark on Retainer 3. Tighten twenty bolts in numerical order on one 4. If the oil seal requires replacement, use the J–42985 side bank as shown in the illustration.
  • Page 778 ENGINE MECHANICAL 6A–65 5. Tighten bolt for camshaft drive gear pulley to the specified torque using the J–43041 universal holder. Torque: 98 N·m (72 lb ft) 014RW060...

  • Page 779: Crankshaft

    6A–66 ENGINE MECHANICAL Crankshaft Crankshaft and Associated Parts 013RW009 Legend (8) Piston and Connecting Rod Assembly (1) Cylinder Head Assembly (9) Flywheel (2) Crankcase with Oil Pan (10) Rear Oil Seal Retainer and Oil Seal (3) Oil Pipe and O-Ring (11) Main Bearing Cap (4) Oil Strainer and O-Ring (12) Crankshaft...

  • Page 780: Disassembly

    ENGINE MECHANICAL 6A–67 Disassembly 2. Remove the main bearing cap fixing bolts in the sequence shown in the illustration. 1. Remove cylinder head assembly (1). Refer to Arrange the removed main bearing caps in the “Cylinder Head” in this manual. cylinder number order.

  • Page 781: Inspection And Repair

    6A–68 ENGINE MECHANICAL 9. Install main bearing caps, oil gallery and crank case Standard : 0.019 mm–0.043 mm bolts in the order shown, and tighten each bolt to the (0.0007 in–0.0017 in) specified torque. Limit : 0.08 mm (0.0031 in) NOTE: Do not apply engine oil to the crank case side bolts.
  • Page 782 ENGINE MECHANICAL 6A–69 2. Measure the diameter and the uneven wear of main 2. Diameter size mark (1). journal and crank pin. If the crankshaft wear exceeds The diameter size marks are stamped on the No.1 the specified limit, crankshaft must be replaced. crankshaft balancer as shown in the illustration.

  • Page 783: Reassembly

    6A–70 ENGINE MECHANICAL Crank Crank Shaft Shaft 1 Size Main Bearing Crank Shaft Main 2 Size Bearing Bearing Oil Clearance Mark Bore Diameter Journal Diameter Mark Size Mark Size Mark (Reference) (Upper (Lower Side) Side) 63.918-63.925 0.030-0.049 Blue Blue (2.5165-2.5167) (0.0012-0.0019) 68.994-69.000 (2.7163-2.7165)
  • Page 784 ENGINE MECHANICAL 6A–71 015RW002 015RS017 3. Flywheel (9) Legend 1. Thoroughly clean and remove the oil from the (1) Around Bolt Holes threads of crankshaft. (2) Around Dowel Pin 2. Remove the oil from the crankshaft and flywheel D Apply engine oil to the oil seal lip. mounting faces.
  • Page 785 6A–72 ENGINE MECHANICAL 4. Piston and connecting rod assembly (8) D Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Check to see that the piston ring end gaps are correctly positioned. 015RS020 5. Install oil gallery (7) and tighten the bolts in 2 steps, in the order shown.
  • Page 786 ENGINE MECHANICAL 6A–73 013RW010 012RS001 7. Install oil pump assembly (5), refer to “Oil pump” in Legend this manual. (1) Portion Between Bolt Holes 8. Install oil strainer and O-ring (4). (2) Bolt Hole Portion 9. Install oil pipe and O-ring (3) and tighten the bolts. 11.

  • Page 787: Piston And Connecting Rod

    6A–74 ENGINE MECHANICAL Piston and Connecting Rod Piston, Connecting Rod and Associate Parts 015RW019 Legend (7) Piston and Connecting Rod Assembly (1) Cylinder Head Assembly (8) Piston Ring (2) Cylinder Head Gasket (9) Piston Pin (3) Crankcase with Oil Pan (10) Piston (4) Oil Pipe and O-Ring (11) Connecting Rod...

  • Page 788: Inspection And Repair

    ENGINE MECHANICAL 6A–75 015RS031 015RS023 D Remove any ridge or carbon build up from the top Legend end of the cylinder. (1) Press Ram 9. Remove the piston rings (8) with a piston ring (2) Piston expander. Arrange the removed piston rings in the (3) Connecting Rod cylinder number order.
  • Page 789 6A–76 ENGINE MECHANICAL 015RV014 012RS002 The size mark (1) for piston outside diameter is Piston Rings (8) represented as shown in illustration below. Any worn or damaged part discovered during engine Outside Diameter overhaul must be replaced with a new one. Size Mark A : 93.360 mm–93.370 mm 1.
  • Page 790 ENGINE MECHANICAL 6A–77 015RS026 015RS028 D Positioning mark (1) is painted as shown in the Piston Pin (9) illustration. NOTE: Do not reuse the old piston pin. Marked T : No.1 Compression ring 1. Use a micrometer to measure the new piston pin Marked T2 : No.2 Compression ring outside diameter in both directions at three different positions.
  • Page 791 6A–78 ENGINE MECHANICAL 3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced.

  • Page 792: Reassembly

    ENGINE MECHANICAL 6A–79 5. Remove the rod caps. 7. Clean the plastigage from the bearings and the crankshaft pins. 6. Measure the width of the plastigage and determine the oil clearance. If the oil clearance Con–rod Bearing Selection exceeds the limit, replace the rod bearing as a Select and install the new connecting rod bearings, set.
  • Page 793 6A–80 ENGINE MECHANICAL D With J–24086–C Piston pin service set and a press, D Install piston rings in the following sequence. press fit the piston pin. 1. Oil ring 1. Expander ring NOTE: Heat the connecting rod small end to a suitable temperature to ensure smooth installation.

  • Page 794: Cylinder Block

    ENGINE MECHANICAL 6A–81 Cylinder Block Cylinder Block and Associated Parts 012RW010 Legend (8) Oil Gallery (1) Cylinder Head Assembly (9) Piston and Connecting Rod Assembly (2) Cylinder Head Gasket (10) Flywheel (3) Crankcase with Oil Pan (11) Rear Oil Seal Retainer Assembly (4) Oil Pipe and O-Ring (12) Main Bearing Cap (5) Oil Strainer and O-Ring...

  • Page 795: Inspection And Repair

    6A–82 ENGINE MECHANICAL 11. Remove rear oil seal retainer assembly. Cylinder Bore 12. Remove main bearing cap. Use a cylinder gauge to measure the cylinder bore 13. Remove crankshaft. diameter in both the axial and thrust directions. Each measurement should be made at six points. 14.

  • Page 796: Reassembly

    ENGINE MECHANICAL 6A–83 D The ”Grade” mark (1) is stamped at the position D Carefully mount the crankshaft. illustrated. D Apply engine oil to the thrust washer. D Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft. 012RS006 Reassembly 015RS013...
  • Page 797 6A–84 ENGINE MECHANICAL D Apply engine oil to oil seal lip and align a dowel pin 5. Install piston and connecting rod assembly. hole in the cylinder block with that in the retainer. D Apply engine oil to the cylinder bores, the D Tighten retainer fixing bolts to the specified torque.
  • Page 798 ENGINE MECHANICAL 6A–85 6. Install oil gallery and tighten the bolts in 2 steps in the 8. Install oil pump assembly. Refer to “Oil Pump” in this order shown. manual. 1st step : 29 N·m (22 lb ft) 9. Install oil strainer and O-ring. 2nd step : 55°∼...

  • Page 799: Main Data And Specification

    6A–86 ENGINE MECHANICAL Main Data and Specification General Specification Specifications Item Item 6VE1 Engine type, number of cylinders and arrangement Water cooled, four cycle V6 Form of combustion chamber Pent roof type Valve mechanism 4-Cams, 4-Valves, DOHC Gear & Belt Drive Cylinder liner type Casted in cylinder drive Total piston displacement...
  • Page 800 ENGINE MECHANICAL 6A–87 Torque Specifications Ignition coil, Spark plug, Crankshaft position sensor and Under cover E06RY001...
  • Page 801 6A–88 ENGINE MECHANICAL Cylinder head cover, Cylinder head, Camshaft bearing cap, Common chamber, EGR valve and EGR pipe, Ion sensing module E06RY00001...
  • Page 802 ENGINE MECHANICAL 6A–89 Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt cover, Oil pump, Oil gallery, Oil strainer and Water pump E06RW002...
  • Page 803 6A–90 ENGINE MECHANICAL Connecting rod and Water pump E06RW011...
  • Page 804 ENGINE MECHANICAL 6A–91 Engine mount E06RW003...

  • Page 805: Special Tool

    6A–92 ENGINE MECHANICAL Special Tool TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–42985 J–21687–02 Installer; Camshaft oil Remover; tie rod end seal J–36390 J–39206 Wrench; Oil filter Installer; Pilot bearing J–8062 Compressor; Valve spring (1) J–8614–01 J–42898 Holder;...
  • Page 806 ENGINE MECHANICAL 6A–93 TOOL NO. ILLUSTRATION TOOL NAME J–24239–1 Cylinder head bolt wrench J–42899 Replacer; Valve guide (1, 2) J–42687 Installer; Valve guide (1) J–37985–1 Remover; Valve guide J–42689 Adjusting Tool: Valve clearance J–42686 Lever; Gear spring J–43041 Holder; Universal...

  • Page 807: Engine Cooling

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 808: General Description

    6B–2 ENGINE COOLING General Description 030RW001 Legend (7) Cylinder Head (1) Water Pump (8) Right Bank (2) Thermostat (9) Throttle Body (10) Cylinder Block (3) Radiator (4) Reserve Tank (11) Cylinder Head (5) Cooling Fan (12) Left Bank (6) Cylinder Block (13) Heater The cooling system is a pressurized Engine Coolant (EC) forced circulation type which consists of a water pump,...
  • Page 809 Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system. D Calculating mixing ratio 031RW002 Radiator The radiator is a tube type with corrugated fins.
  • Page 810 6B–4 ENGINE COOLING B06RW002 B06RW003 D Mixing ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from 0°C to 50°C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. NOTE: 1.

  • Page 811: Diagnosis

    6B–5 ENGINE COOLING Diagnosis Engine Cooling Trouble Condition Possible cause Correction Engine overheating Low Engine Coolant level Replenish Incorrect fan installed Replace Thermo meter unit faulty Replace Faulty thermostat Replace Faulty Engine Coolant temperature Repair or replace sensor Clogged radiator Clean or replace Faulty radiator cap Replace...

  • Page 812: Draining And Refilling Cooling System

    6B–6 ENGINE COOLING Draining and Refilling Cooling 9. After the engine has cooled, replenish with EC up to the “MAX” line of the reserve tank. System 10. Start the engine. With the engine running at 3,000 Before draining the cooling system, inspect the system rpm, make sure there is no running water sound from and perform any necessary service to ensure that it is the heater core (behind the center console).

  • Page 813: Water Pump

    6B–7 ENGINE COOLING Water Pump Water Pump and Associated Parts 030RS002 Legend (3) Water Pump Assembly (1) Timing Belt (4) Gasket (2) Idle Pulley Removal 2. Install water pump assembly and tighten bolts to the specified torque. 1. Disconnect battery ground cable. Torque: 25 N·m (18 lb ft) 2.

  • Page 814: Thermostat

    6B–8 ENGINE COOLING 3. Idle pulley 4. Timing belt D Install idle pulley and tighten bolt to the specified D Install timing belt. Refer to timing belt installation torque. step in “Timing Belt” in this manual. 5. Connect radiator inlet hose and replenish EC. Torque: 52 N·m (38 lb ft) 6.

  • Page 815: Radiator

    6B–9 ENGINE COOLING Radiator Radiator and Associated Parts 110RW003 Legend (4) Reserve Tank Hose (1) Oil Cooler Hose For Automatic Transmission (5) Bracket (2) Radiator Hose (6) Radiator Assembly (3) Fan Guide, Lower (7) Reserve Tank Removal 5. Remove fan guide(1), clips(3) on both sides and the bottom lock, then remove lower fan guide(3) with fan 1.

  • Page 816: Inspection

    6B–10 ENGINE COOLING Valve opening vacuum kPa (psi) 1.96 ∼ 4.91 6. Disconnect the reserve tank hose(4) from radiator. (0.28 ∼ 0.71) 7. Remove bracket(5). 110RS006 110RW004 8. Lift up and remove the radiator assembly with hose, Radiator Core taking care not to damage the radiator core with a fan blade.

  • Page 817: Installation

    ENGINE COOLING 6B–11 Cap tester: J–24460–01 8. Connect battery ground cable. Adapter: J–33984–A 9. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank. 110RS005 111RS001 Installation Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant.

  • Page 818: Drive Belt And Cooling Fan

    6B–12 ENGINE COOLING Drive Belt and Cooling Fan Drive Belt and Associated Parts 015RW005 Legend (4) Water Pump and Cooling Fan Pulley (1) Crankshaft Pulley (5) Idle Pulley (2) Generator (6) Tension Pulley (3) Power Steering Pump (7) Drive Belt The drive belt adjustment is not required as automatic Installation drive belt tensioner is equipped.

  • Page 819: Main Data And Specifications

    ENGINE COOLING 6B–13 Main Data and Specifications General Specifications Cooling system Engine coolant forced circulation Radiator (1 tube in row) Tube type corrugated (2 tube in row) Heat radiation capacity 68,000 kcal/h 77,000 kcal/h Heat radiation area 9.445m@ (0.878ft@) 11.21m@ (1.04ft@) Radiator front area 0.302m@ (0.028ft@) Radiator dry weight...

  • Page 820: Special Tool

    6B–14 ENGINE COOLING Special Tool TOOL NO. ILLUSTRATION TOOL NAME J–24460–01 Tester; radiator cap J–33984–A Adapter; radiator cap...

  • Page 821: Engine Fuel

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 822: General Description

    6C–2 ENGINE FUEL General Description 140RY00002 Legend (8) Fuel Rail Left (1) Fuel Filler Cap (9) Left Bank (2) Fuel Tank (10) Fuel Pressure Control Valve (3) Rollover Valve (11) Common Chamber (4) Fuel Pump (Fuel Level Sending Unit/Fuel Tank (12) Duty Solenoid Valve Pressure Sensor) (13) Throttle Valve...

  • Page 823: Fuel Metering

    ENGINE FUEL 6C–3 D Adhere to all Notices and Cautions. All gasoline engines are designed to use only unleaded gasoline. Unleaded gasoline must be used for proper emission control system operation. Its use will also minimize spark plug fouling and extend engine oil life.

  • Page 824: Fuel Filter

    6C–4 ENGINE FUEL Fuel Filter Fuel Filter and Associated Parts 041RW014 Legend (3) Fuel Filter Fixing Bolt (1) Fuel Filler Cap (4) Fuel Filter (2) Fuel Hose Removal Inspection 1. Replace the fuel filter if the fuel leaks from fuel filter CAUTION: When repair to the fuel system has been body or if the fuel filter body itself is damaged.

  • Page 825: Inspection

    ENGINE FUEL 6C–5 3. Connect fuel hoses on engine side(1) and fuel tank 4. Connect the pump relay terminals with a jumper side(2). wire(1) as shown and start the fuel pump to measure delivery. 041RW001 4. Install fuel filler cap 140RW002 5.

  • Page 826: Fuel Pump

    6C–6 ENGINE FUEL Fuel Pump Fuel Pump and Associated Parts 035RW030 Removal Installation 1. Install FP assembly(2). CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system 2. Install fuel tank assembly(1). Refer to “Fuel Tank for loose connection or leakage.

  • Page 827: Fuel Pump Relay

    ENGINE FUEL 6C–7 Fuel Pump Relay General Description When it is turned to “START” position, the Power Train Control Module (PCM) receives the reference pulse from In order to control the FP operation, the FP relay is the Ignition Control Module and it operates the relay, provided.

  • Page 828: Installation

    6C–8 ENGINE FUEL D Install a flange on left side on the bracket from the 7. Disconnect two fuel tank wiring connectors(4) on front right side of tank. bottom, and tighten bolts to the specified torque. 8. Disconnect evapo fuel hose(5). Torque: 36 N·m (27 lb ft) 9.
  • Page 829 ENGINE FUEL 6C–9 2. For removal of the delivery pipe (feeding fuel to the NOTE: This work should be done by hands. Do not use engine), hold the connector in one hand, and hold the any tools. Should the pipe can hardly be removed from retainer tab with the other hand and pull out the the connector, use a lubricant (light oil) and/or push and connector, as illustrated.

  • Page 830: Reuse Of Quick-Connector

    6C–10 ENGINE FUEL Reuse of Quick–Connector (Delivery Pipe) D Replace the pipe and connector if scratch, dent or crack is found. D Remove mud and dust from the pipe and make sure that the end including spool is free of defects, such as scratch, rust, and dent, which may cause poor sealability.

  • Page 831: Fuel Gauge Unit

    ENGINE FUEL 6C–11 Fuel Gauge Unit Fuel Gauge Unit and Associated Parts 140RS004 Legend (1) Wiring Connector (2) Fuel Gauge Unit Removal Installation 1. Fuel gauge unit(2). CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system 2.

  • Page 832: Fuel Filler Cap

    6C–12 ENGINE FUEL Fuel Filler Cap General Description Legend (1) Vacuum Valve Fuel filler cap includes vacuum valve and pressure valve. (2) Pressure Valve In case any high vacuum and any high pressure happen in tank, each valve works to adjust the pressure to prevent the tank from being damaged.

  • Page 833: Engine Electrical

    SECTION ENGINE ELECTRICAL 6D1–1 TROOPER ENGINE ENGINE ELECTRICAL CONTENTS Battery ....... . . 6D1–1 Jump Starting .

  • Page 834: Battery

    6D1–2 ENGINE ELECTRICAL 3. Fluid Level Check a. VOLTAGE DOES NOT DROP BELOW THE MINIMUM LISTED IN THE TABLE – The battery is The fluid level should be between the upper level line(2) good and should be returned to service. and lower level line(3) on side of battery.

  • Page 835: Battery Removal

    ENGINE ELECTRICAL 6D1–3 Treat both the discharged battery and the booster 4. Attach one end of the remaining cable to the negative battery with great care when using jumper cables. terminal of the booster battery. Carefully follow the jump starting procedure, being Attach the other end of the same cable to a solid careful at all times to avoid sparking.

  • Page 836: Main Data And Specifications

    6D1–4 ENGINE ELECTRICAL Main Data and Specifications General Specifications Model (JIS) 95D31R–MF 80D26R–MF 75D26R–MF Voltage (V) Cold Cranking Performance (Amp) Reserve Capacity (Min) Load Test (Amp) Fast Charge Maximum Amperage (Amp) BCI Group No.

  • Page 837: Ignition System

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 838: General Description

    6D2–2 IGNITION SYSTEM General Description Ignition is done by the electronic ignition (El) that directly The ignition coils are connected with the PCM by means fires the spark plugs from ignition coils through spark plug of a 80 pin connector. wires without using a distributor.

  • Page 839: Ignition Coil

    IGNITION SYSTEM 6D2–3 Ignition Coil Removal Measure resistance of ignition coil assembly, and replace the ignition coil assembly if its value exceeds the 1. Disconnect battery ground cable. standard. 2. Ignition coil connector and ignition coil. D Disconnect three connector from ignition coil. D Remove harness bracket bolt on cylinder head cover.
  • Page 840 6D2–4 IGNITION SYSTEM CAUTION: Ignition coil assembly # 6 is different from ignition coil assembly from # 1 to # 5. Ignition coil assembly # 6 is short type. So, note it when installing ignition coil assembly of # 6. 060RY00002 Legend (1) Long Type Ignition Coil Assemblies (# 1 ∼...

  • Page 841: Spark Plug

    IGNITION SYSTEM 6D2–5 Spark Plug Removal 1. Remove spark plugs. Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. D Check electrode and insulator for presence of cracks, and replace if any. D Check electrode for wear, and replace if necessary.

  • Page 842: Crankshaft Position Sensor

    6D2–6 IGNITION SYSTEM Crankshaft Position Sensor Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block. 012RS008 Installation 1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O–ring.

  • Page 843: Main Data And Specifications

    IGNITION SYSTEM 6D2–7 Main Data and Specifications General Specifications Ignition System Ignition Form Electronic Ignition System (El system) with Crankshaft position Sensor Spark Plug Type K16PR–P11 RC10PYP4 PK16PR11 Plug gap 1.0 mm (0.04 in) – 1.1 mm (0.043 in) Torque 18 N·m (13 lb ft) Torque Specifications E06RY001...
  • Page 844 When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 845: Starting System

    STARTING AND CHARGING SYSTEM 6D3–2 Starting System General Description Cranking Circuit The cranking system consists of a battery, starter, starter switch, starter relay, etc. These main components are connected. Starter The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft.
  • Page 846 STARTING AND CHARGING SYSTEM 6D3–3 C06RY00002...

  • Page 847: Diagnosis

    STARTING AND CHARGING SYSTEM 6D3–4 Diagnosis Condition Possible cause Correction Starter does not run Charging failure Repair charging system Battery Failure Replace Battery Terminal connection failure Repair or replace terminal connector and/or wiring harness Starter switch failure Repair or replace starter switch Starter failure Repair or replace starter...

  • Page 848: Starter

    STARTING AND CHARGING SYSTEM 6D3–5 Starter Removal 2. Install mounting bolts and tighten bolts to specified torque(5). 1. Battery ground cable. Torque: 40 N·m (30 lb ft) 2. Disconnect Heated O Sensor connector (1). 3. Reconnect the connectors to terminals “B” and “S” 3.

  • Page 849: Disassembled View

    STARTING AND CHARGING SYSTEM 6D3–6 Disassembled View 065RW002 Legend (14) Center Bracket (1) Bolt (2 pcs) (15) Pinion Shaft (2) Ball Bearing (16) Planet Gear (3) (3) Pinion (17) Internal Gear (4) Shift Lever (18) Center Bracket (A) (5) Dust Cover (19) Yoke Assembly (6) Torsion Spring (20) Armature...

  • Page 850: Disassembly

    STARTING AND CHARGING SYSTEM 6D3–7 Disassembly 7. Remove screw (2 pcs) (8). 8. Remove through bolt (2 pcs) (7). 1. Loosen the nut(1) on terminal “M” of magnetic switch 9. Remove screws and through bolts, then the rear and disconnect the connector cable. cover(9) then remove thrust washer(10).
  • Page 851 STARTING AND CHARGING SYSTEM 6D3–8 12. Remove yoke assembly(14). 17. Remove ball bearing(19). 13. Remove armature(15). 18. Remove bearing cover(20). 14. Pull off the yoke assembly, then remove armature, 19. Remove a ball bearing and bearing cover from the washer and center bracket.(A) (13). gear case(18).

  • Page 852: Inspection And Repair

    STARTING AND CHARGING SYSTEM 6D3–9 22. Remove an E–ring(23) from the pinion shaft using a Inspection and Repair flat blade screwdriver. Repair or replace necessary parts if extreme wear or damage is found during inspection. Armature Measure the outer diameter of commutator, and replace with a new one if it is out of the limit.
  • Page 853 6D3–10 STARTING AND CHARGING SYSTEM Check for continuity between commutator and shaft. Polish the commutator surface with sandpaper #500 to Also, check for continuity between commutator and #600 if it is rough. armature core,armature core and shaft. Replace commutator if there is continuity (i.e., internally grounded).
  • Page 854 STARTING AND CHARGING SYSTEM 6D3–11 Brush Magnetic Switch Measure the length of brush. Check for continuity of shunt coil between terminals S and Replace with a new one, if it is below the limit. Replace, if there is no continuity (i.e., coil is Standard: 16 mm (0.63 in) disconnected).
  • Page 855 6D3–12 STARTING AND CHARGING SYSTEM Continuity of Contacts Yoke Assembly With the plunger faced downward, push down the Check a magnet inside the yoke. magnetic switch. In this state, check for continuity Replace the yoke assembly if it is broken. between terminals B and M.

  • Page 856: Reassembly

    STARTING AND CHARGING SYSTEM 6D3–13 Measure inner diameter of bushing in the rear cover, and Reassembly replace if it exceeds the limit. To install, follow the removal steps in the reverse order, Standard: 12.50 mm to 12.527 mm (0.492 in to noting the following points: 0.4932 in) Grease application places...
  • Page 857 6D3–14 STARTING AND CHARGING SYSTEM If the measured value is out of standard, insert dust cover, or disassemble and adjust. 065RW019 Characteristic Test For easily confirming the characteristics, conduct the no load test as follows: Rating as short as 30 seconds requires rapid testing. Fix the starter on the test bench, and wire as shown in illustration.

  • Page 858: Main Data And Specifications

    STARTING AND CHARGING SYSTEM 6D3–15 Main Data and Specifications General Specifications Model HITACHI GD003138 Rating Voltage 12 V Output 1.4 Kw Time 30 sec Number of teeth of pinion Rotating direction(as viewed from pinion) Clockwise Weight(approx.) 34 N No load characteristics Voltage /Current 11V/90A or less Speed...
  • Page 859 6D3–16 STARTING AND CHARGING SYSTEM Torque Specifications E06RW023...
  • Page 860 STARTING AND CHARGING SYSTEM 6D3–17 E06RW024...

  • Page 861: Charging System

    6D3–18 STARTING AND CHARGING SYSTEM Charging System General Description General On–Vehicle Inspection The operating condition of charging system is indicated The IC integral regulator charging system and its main by the charge warning lamp. The warning lamp comes on components are connected as shown in the illustration. when the starter switch is turned to “ON”...

  • Page 862: Generator

    STARTING AND CHARGING SYSTEM 6D3–19 Generator Removal 1. Disconnect battery ground cable. 2. Move drive belt tensioner to loose side using wrench then remove drive belt (1). 3. Disconnect the wire from terminal “B” and disconnect the connector (4). 4. Remove generator fixing bolt (3). 5.

  • Page 863: Disassembled View

    6D3–20 STARTING AND CHARGING SYSTEM Disassembled View 066RW007 Legend (6) Rectifier (1) Pulley Nut (7) Terminal Insulator and Nut (2) Pulley (8) Regulator Assembly (3) Front Cover Assembly (9) Brush Holder Assembly (4) Rotor Assembly (10) Rear Cover (5) Rear End Cover...

  • Page 864: Disassembly

    STARTING AND CHARGING SYSTEM 6D3–21 Disassembly 4. Remove three screws on the IC regulator, then the IC regulator assembly(6). 1. Terminal insulator and nut(2). 2. Remove three nuts(1) on the rear cover and a nut on terminal B and insulator, then remove the rear cover(3).
  • Page 865 6D3–22 STARTING AND CHARGING SYSTEM 6. Secure the pulley directly in the vise between two 8. Use the puller to remove the rear end cover. copper plates, and remove the nut and pulley. 9. Rotor assembly 066RS010 066RS012 7. Remove four nuts(8) that secure the front cover 10.

  • Page 866: Inspection And Repair

    STARTING AND CHARGING SYSTEM 6D3–23 Inspection and Repair 3. Check resistance between slip rings, and replace if there is no continuity. Repair or replace necessary parts if extreme wear or damage is found during inspection. Rotor Assembly 1. Check the rotor slip ring surfaces for contamination and roughness.
  • Page 867 6D3–24 STARTING AND CHARGING SYSTEM Stator Coil Rectifier Assembly Check for continuity across “P” and “E” in the 100W 1. Measure resistance between respective phases. range of multimeter. 2. Measure insulation resistance between stator coil and core with a mega–ohmmeter. If less than standard, replace the coil.

  • Page 868: Reassembly

    STARTING AND CHARGING SYSTEM 6D3–25 Reassembly Bench Test To reassemble, follow the disassembly steps in the Conduct a bench test of the generator. reverse order, noting the following points: 1. Using a press with a socket wrench attached, reassemble rotor and rear end cover assembly in the front cover.

  • Page 869: Main Data And Specifications

    6D3–26 STARTING AND CHARGING SYSTEM Main Data and Specifications General Specifications Parts Number (Nippon denso) 102211—1740 Model ACJV74 Rated voltage 12 V Rated output 90 A Rotating direction (As viewed from pulled) Clockwise Pulley effective diameter 57.5 mm (2.26 in) Weight 49.7 N (11.2 lb)
  • Page 870 SECTION TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–1 TROOPER ENGINE TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS CONTENTS Specifications ......6E–6 Serial Data Communications .
  • Page 871 6E–2 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Fuel Trim System Monitor Diagnostic Diagnostic Aids ......6E–101 Operation .
  • Page 872 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–3 P0137 HO2S Circuit Low Voltage P0401 EGR Flow Insufficient ... . . 6E–310 Bank 1 Sensor 2 ......6E–185 P0402 EGR Pintle Crank Error .
  • Page 873 6E–4 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS P1169 Fuel System Rich During Decel Fuel Service Precaution ....6E–534 Cut Off (Bank 2) .
  • Page 874 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–5 Mass Air Flow (MAF) Sensor ... . 6E–565 Run Mode ......6E–571 Manifold Absolute Pressure (MAP) Sensor 6E–565...

  • Page 875: Specifications

    6E–6 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Specifications Tightening Specifications Application N·m Lb Ft. Lb In. Camshaft Position Sensor Retaining Screw — Crankshaft Position Sensor Mounting Bolt — EGR Bolt — Engine Coolant Temperature Sensor — Fuel Drain Plug —...

  • Page 876: Diagrams And Schematics

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–7 Diagrams and Schematics PCM Wiring Diagram (1 of 7) D06RY00156...

  • Page 877: Pcm Wiring Diagram (2 Of 7)

    6E–8 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram (2 of 7) D06RY00150...

  • Page 878: Pcm Wiring Diagram (3 Of 7)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–9 PCM Wiring Diagram (3 of 7) D06RY00042...

  • Page 879: Pcm Wiring Diagram (4 Of 7)

    6E–10 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram (4 of 7) D06RY00044...

  • Page 880: Pcm Wiring Diagram (5 Of 7)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–11 PCM Wiring Diagram (5 of 7) D06RY00149...

  • Page 881: Pcm Wiring Diagram (6 Of 7)

    6E–12 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram (6 of 7) D06RY00115...

  • Page 882: Pcm Wiring Diagram (7 Of 7)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–13 PCM Wiring Diagram (7 of 7) D06RY00127...

  • Page 883: Pcm Pinouts

    6E–14 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinouts PCM Pinout Table, 80-Way Blue Connector – Row “F1 ∼ 20” 060RY00045 PIN Function Wire Color IGN ON ENG RUN Refer To PCM Ground BLK/BLU 0.0V 0.0V Chassis Electrical 5Volt Referrence“2” (AP 5.0V 5.0V AP Sensor...
  • Page 884 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–15 PIN Function Wire Color IGN ON ENG RUN Refer To Ignition Feed RED/GRN 6D Section Ignition Feed RED/WHT 6D Section...

  • Page 885: Pcm Pinout Table, 80-Way Blue Connector - Row "F20

    6E–16 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 80-Way Blue Connector – Row “F20 ∼ 40” 060RY00156 PIN Function Wire Color IGN ON ENG RUN Refer To Bank 1 HO2S 1 Ground 0.0V 0.0V General Description and Operation, Catalyst Monitor HO2S 1 Not Used...
  • Page 886 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–17 PIN Function Wire Color IGN ON ENG RUN Refer To Brake Swich GRN/YEL 0.0V 0.0V 4L30E T/Mission PCM Ground BLK/RED 0.0V 0.0V Chassis Electrical...
  • Page 887 6E–18 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 80-Way Blue Connector – Row “F41 ∼ 60” 060RY00046 PIN Function Wire Color IGN ON ENG RUN Refer To Throttle Position(TP) 1 0.0V 0.0V General Description and Sensor Ground Operation,TPS Fuel Pump Relay SIL/BLK...
  • Page 888 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–19 PIN Function Wire Color IGN ON ENG RUN Refer To Not Used — — — — Shielded Wire 0.0V 0.0V Chassis Electrical...

  • Page 889: Pcm Pinout Table, 80-Way Blue Connector - Row "F61

    6E–20 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 80-Way Blue Connector – Row “F61 ∼ 80” 060RY00047 PIN Function Wire Color IGN ON ENG RUN Refer To Throttle Position(TP) 2 GRN/WHT 0.0V 0.0V General Description and Sensor Ground Operation,TPS Injector Cylinder #2 GRN/ORN...
  • Page 890 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–21 PIN Function Wire Color IGN ON ENG RUN Refer To Mode Switch BLU/WHT 4L30E T/Mission Mode Switch BLU/BLK 4L30E T/Mission Mode Switch BLU/YEL 4L30E T/Mission AP Sensor 2 Sensor 0.0V 0.0V General Description and Ground Operation, APS...

  • Page 891: Pcm Pinout Table, 80-Way Red Connector - Row "S1

    6E–22 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 80-Way Red Connector – Row “S1 ∼ 20” 060RY00069 PIN Function Wire Color IGN ON ENG RUN Refer To PCM Ground BLK/WHT 0.0V 0.0V Chassis Electrical Bank 1 HO2S 1 Heater 0.0V 0.0V General Description and...
  • Page 892 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–23 PIN Function Wire Color IGN ON ENG RUN Refer To Bank 1 HO2S 1 Low 0.0V 0.1V General Description and Operation, Catalyst Monitor HO2S ION Sensing Module RED/YEL 1.555V 1.555V General Description and Operation, ION Sensing Module Transmission Fluid...

  • Page 893: Pcm Pinout Table, 80-Way Red Connector - Row "S21

    6E–24 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 80-Way Red Connector – Row “S21 ∼ 40” 060RY00049 PIN Function Wire Color IGN ON ENG RUN Refer To Not Used — — — — Transmissin Output Speed 0.0V 0.0V 4L30E T/Mission Sensor...
  • Page 894 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–25 PIN Function Wire Color IGN ON ENG RUN Refer To Auto Cruise Lamp BLK/ORN 0.0V 0.0V Chassis Electrical PCM Ground 0.0V 0.0V Chassis Electrical...

  • Page 895: Pcm Pinout Table, 80-Way Red Connector - Row "S41

    6E–26 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 80-Way Red Connector – Row “S41 ∼ 60” 060RY00050 PIN Function Wire Color IGN ON ENG RUN Refer To AP Sensor 3 Sensor BLU/ORN 0.0V 0.0V General Description and Ground Operation, APS Bank 2 HO2S 1 Heater...
  • Page 896 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–27 PIN Function Wire Color IGN ON ENG RUN Refer To Bank 2 HO2S 1 High 0.3V 0.1–0.9V General Description and Operation, Catalyst Monitor HO2S Auto Cruise Steering Set Light GRN 0.0V 0.0V Chassis Electrical Switch Fuel Sender Unit...

  • Page 897: Pcm Pinout Table, 80-Way Red Connector - Row "S61

    6E–28 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 80-Way Red Connector – Row “S61 ∼ 80” 060RY00051 PIN Function Wire Color IGN ON ENG RUN Refer To Intake Air Temperature 0.0V 0.0V General Description and (IAT)Sensor Ground Operation, IAT ION Sensing Module 1.555V...
  • Page 898 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–29 PIN Function Wire Color IGN ON ENG RUN Refer To 5Volt Referrence (AP 5.0V 5.0V Appropriate Sensor Sensor 3) Accelerate Position(AP) 0.41–0.45V 0.41–0.45V General Description and Sensor 2 Operation,AP Sensor Accelerate Position(AP) BLU/GRN 4.55–4.99V 0.41–0.45V...

  • Page 899: Component Locators

    6E–30 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Component Locators Engine Component Locator 060RY00070...

  • Page 900: Engine Component Locator Table

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–31 Engine Component Locator Table Number Name Location Linear Exhaust Gas Recirculation (EGR) Valve Rear right side of the engine Throttle Position (TP) Sensor On the throttle body Intake Air Temperature (IAT) Sensor On the intake air duct near the throttle body Check Engine (MIL) Light On the instrument panel beneath the...

  • Page 901: Undercarriage Component Locator

    6E–32 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Undercarriage Component Locator F00RW032 Undercarriage Component Locator Table Number Name Location Fuel Pump Assembly Installed in the top of the fuel tank EVAP Canister On the top of the bracket that is located behind of the cross member EVAP Canister Cut Valve On the top of the bracket that is located behind...

  • Page 902: Fuse And Relay Panel (Underhood Electrical Center)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–33 Fuse and Relay Panel (Underhood Electrical Center) 065RY00003...

  • Page 903: Sensors And Miscellaneous Component Locators

    6E–34 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Sensors and Miscellaneous Component Locators 060RY00013 060RX00005 T321067 060RW111 T321068 141RY00001...
  • Page 904 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–35 055RY00002 T321078 041RW004 060RY00014 025RW005 060RY00016...
  • Page 905 6E–36 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 060RY00023...

  • Page 906: Diagnosis

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–37 Diagnosis 3. Use a check sheet or other method to identify the circuit or electrical system component. Strategy-Based Diagnostics 4. Follow the suggestions for intermittent diagnosis found in the service documentation. Strategy-Based Diagnostics Most Scan Tools, such as the Tech 2, have data-capturing capabilities that can assist in detecting intermittents.

  • Page 907: General Service Information

    MIL (“Check Engine” vehicle. If the label has been removed it should be lamp). replaced. It can be ordered from Isuzu Dealership. Environment Visual / Physical Engine Compartment Temporary environmental conditions, such as localized Inspection flooding, will have an effect on the vehicle ignition system.

  • Page 908: Basic Knowledge Of Tools Required

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–39 D Inspect all vacuum hoses for pinches, cuts, When a diagnostic test reports a fail result, the diagnostic disconnections, and proper routing. executive records the following data: D The diagnostic test has been completed since the last D Inspect hoses that are difficult to see behind other ignition cycle.

  • Page 909: System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations

    6E–40 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS D Cruise control inhibit D EGR D Catalyst monitoring Refer to PCM and Sensors in General Descriptions. Passive and Active Diagnostic Tests Enable Criteria A passive test is a diagnostic test which simply monitors a The term “enable criteria”...

  • Page 910: Dtc Types

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–41 D Freeze Frame data for the first emission related DTC D The diagnostic tests that are passed must occur recorded within 375 RPM of the RPM data stored at the time the last test failed.
  • Page 911 6E–42 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS (Some special conditions apply to misfire and fuel trim Storing and Erasing Freeze Frame Data and Failure DTCs) Records D Type C (if the vehicle is so equipped) Government regulations require that engine operating D Non-Emissions related conditions be captured whenever the MIL is illuminated.

  • Page 912: Verifying Vehicle Repair

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–43 4. Monitor the DTC status information for the DTC which has been diagnosed until the diagnostic test associated with that DTC runs. Following these steps are very important in verifying repairs on OBD ll systems. Failure to follow these steps could result in unnecessary repairs.

  • Page 913: Tech 2

    6E–44 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Tech 2 From 98 MY, Isuzu dealer service departments are recommended to use the Tech 2 Scan Tool. Please refer to the Tech 2 user guide. 901RW180 Legend (3) SAE 16/19 Adaptor...

  • Page 914: Tech 2 Features

    D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 2000 System PCMCIA card (1) inserts into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4).

  • Page 915: Operating Procedure (For Example)

    6E–46 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Operating Procedure (For Example) The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below. 060RY00072 060RY027...

  • Page 916: Dtc Modes

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–47 Menu D The following table shows which functions are used for the available equipment versions. 060RW223 The following is a brief description of each of the sub menus in DTC Info and DTC. The order in which they appear here is alphabetical and not necessarily the way 060RY00073 they will appear on the Tech 2.

  • Page 917: Miscellaneous Test

    6E–48 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Not Run Since Code Cleared 4. Select F0:Lamps Test in the Miscellaneous Test. This option will display up to DTCs that have not run since the DTCs were last cleared. Since any displayed DTCs have not run, their condition (passing or failing) is unknown.
  • Page 918 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–49 9. Select F2: Up Shift Lamp 17. Select F3:Reduced Power Lamp 060RY00076 060RY00077 10. Push “On” of soft key. 18. Push ”On” of soft key. 11. Make sure Lamp illuminates. 19. Make sure Lamp illuminates. 12.

  • Page 919: Relays Test

    6E–50 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Relays Test 5. Select F0:Fuel Pump Relay. This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1.

  • Page 920: Evap Test

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–51 11. Turn on Air Condtioning. 4. Select F2: EVAP Test in the Miscellaneous Test. 060RY00094 060RY00082 12. Turn “On” and “Off” A/C Switch. 5. Select F0: Purge Solenoid. 13. Contol A/C Clutch Relay and check data list. 14.

  • Page 921: Fuel System Test

    6E–52 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6. Push “Decrease” or “Increase” soft key. 11. Push “On” or “Off” soft key. 060RY00095 060RY00096 7. Control EVAP Purge Solenoid and check a data list. 12. Control EVAP Vent Solenoid and check data list. 8.
  • Page 922 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–53 4. Select F3: Fuel System in the Miscellaneous Menu. 6. Push “Disable” or “Enable” soft key. 060RY00083 060RY00097 5. Select F0: Fuel Trim Enable. 7. Control Fuel Trim and check data list. 8.

  • Page 923: Instruments Test

    6E–54 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 10. Push “Reset” of soft key. 13. Push “Open Loop” or “Closed Loop” soft key. 060RY00098 060RY00099 11. Select F2: O2-Loop status. 14. Control O2-Loop and check data list. 15. If data list changes, the O2-Loop is normal. Instruments Test This test is conducted check Instruments for proper operation.
  • Page 924 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–55 4. Select F4: Instruments in the Miscellaneous Menu. 6. Push “Decrease” or “Increase” soft key. 060RY00106 060RY00100 5. Select F0: Fuel Gauge level. 7. Control Fuel Level and check data list. 8. If data list and Fuel gauge meter changes, Fuel Gauge level is normal.

  • Page 925: Egr Control Test

    6E–56 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 10. Push “Inactive” or “active” soft key. 4. Select F5: EGR Control Test in the Miscellaneous Test. 060RY00101 11. Control tachometer and data list. 060RY00084 5. Control EGR Valve and check data list. 12.
  • Page 926 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–57 2. Ignition SW is “On”. 4. Select F6: Variable Intake Manifold Solenoid Test. 060RY00104 060RY00085 3. Select F3: Miscellaneous Test in the Application 5. Push “On” or “Off” of soft key. Menu. 060RX028 6.

  • Page 927: Injector Balance Test

    6E–58 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Injector Balance Test 5. Select injector number and push “injector off” soft key. This test is conducted to make sure the appropriate electric signals are being sent to injectors Nos. 1–6. Tech 2 must be used for this test. Test Procedure: 1.

  • Page 928: Plotting Graph Flow Chart (Plotting Graph After Obtaining Vehicle Information)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–59 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) D06RY00167...

  • Page 929: Flow Chart For Snapshot Replay (Plotting Graph)

    6E–60 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Flow Chart for Snapshot Replay (Plotting Graph) 060RX040...

  • Page 930: Primary System-Based Diagnostic

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–61 Primary System-Based Diagnostic HO2S Heater Heated oxygen sensors are used to minimize the amount Primary System-Based Diagnostic of time required for closed loop fuel control to begin operation and to allow accurate catalyst monitoring. The There are primary system-based diagnostics which oxygen sensor heater greatly decreases the amount of evaluate system operation and its effect on vehicle...

  • Page 931: Evaporative Emission (Evap) Purge System Vacuum Switch

    6E–62 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS D For 3.5L w/automatic transmission, Aftermarket HO2S characteristics may be different from pre-catalyst sensor are designated Bank 1 HO2S 1 the original equipment manufacturer sensor. This may and Bank 2 HO2S 1. The post-catalyst sensors are lead to a false pass or a false fail of the catalyst monitor Bank 1 HO2S 2 and Bank 2 HO2S 2.

  • Page 932: Fuel Trim System Monitor Diagnostic Operation

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–63 history counters will be updated every 100 cylinder firing vacuum leak or rough idle due to a large vacuum leak) events. A misfire counter is maintained for each cylinder. while it operates fine at other times. No fuel trim DTC If the misfire diagnostic reports a failure, the diagnostic would set (although an engine idle speed DTC or HO2S executive reviews all of the misfire counters before...

  • Page 933: On-Board Diagnostic (Obd Ii) System Check

    6E–64 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS On-Board Diagnostic (OBD II) System Check D06RY00053 Circuit Description 2.The RPL (“Reduced Power lamp”) should be “ON” steady with the ignition “ON ”engine “OFF.”If not, The on-board diagnostic system check is the starting the “No RPL”chart should be used to isolate the point for any driveability complaint diagnosis.
  • Page 934 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–65 On-Board Diagnostic (OBD II) System Check Step Action Value(s) 1. Ignition “ON,”engine “OFF.” 2. Observe the malfunction indicator lamp (MIL or Go to No “Check Engine lamp”). MIL(“Check Is the MIL (“Check Engine lamp”)“ON?” Engine lamp”) —...
  • Page 935 6E–66 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS On-Board Diagnostic (OBD II) System Check (Cont'd) Step Action Value(s) Compare PCM data values displayed on the Tech 2 to Refer to the typical engine scan data values. indicated Component Are the displayed values normal or close to the typical System Go to values?

  • Page 936: A/C Clutch Control Circuit Diagnosis

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–67 A/C Clutch Control Circuit Diagnosis D06RY00159 D The engine coolant temperature (ECT) is greater Circuit Description than 125 °C (257 °F). When air conditioning and blower fan are selected, and if D The intake air temperature (IAT) is less than 5°C the system has a sufficient refrigerant charge, a 12-volt (41°F).

  • Page 937: A/C Clutch Diagnosis

    6E–68 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS A/C Clutch Diagnosis 3. This a test determine is the problem is with the refrigerant system. If the switch is open, A/C This chart should be used for diagnosing the electrical pressure gauges will be used to determine if the portion of the A/C compressor clutch circuit.
  • Page 938 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–69 A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) Temporarily substitute the A/C compressor relay in place of the A/C thermostat relay, then repeat Step 5. Did the “A/C Request” display indicate “Yes?” —...
  • Page 939 6E–70 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) Use an ohmmeter to check continuity between the pressure switch (GRN/WHT) and the A/C thermostat relay (GRN/WHT). Was the circuit open? — Go to Step 22 Go to Step 23 Repair the open circuit between the pressure switch and the A/C thermostat relay.
  • Page 940 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–71 A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) 1. A/C compressor relay removed. 2. Connect a fused jumper at the A/C compressor relay socket between either BRN wire and the BRN/YEL wire. 3.

  • Page 941: Electronic Ignition System Diagnosis

    6E–72 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Electronic Ignition System Diagnosis Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure If the engine cranks but will not run or immediately stalls, the Engine Cranks But Will Not Start chart must be used to determine if the failure is the ignition system or the fuel system.

  • Page 942: Injector Coil Test Procedure (Steps 1-6) And Injector Balance Test Procedure (Steps 7-11)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–73 D An erratic voltage reading (large fluctuations in 7. The Fuel Injector Balance Test portion of this chart voltage that do not stabilize) indicates an (Step 7 through Step 11) checks the mechanical intermittent connection within the fuel injector.
  • Page 943 6E–74 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1.
  • Page 944 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–75 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd) Step Action Value(s) 1. Set injector switch box injector #1. 2. Press the “Push to Start Test” button on the fuel injector tester.
  • Page 945 6E–76 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd) Step Action Value(s) 1. Connect the J 39021-5V Fuel Injector Tester and J 39021-90 Injector Switch Box the fuel injector harness connector.

  • Page 946: Powertrain Control Module (Pcm)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–77 Powertrain Control Module (PCM) The PCM provides the following sensors with a 5–volt reference and a sensor ground signal: Diagnosis To read and clear diagnostic trouble codes, use a Tech 2. D The exhaust gas recirculating (EGR) pintle position IMPORTANT: Use of a Tech 2 is recommended to clear D sensor...
  • Page 947 6E–78 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS D P0453 D P0106, P0107, P1107 D P0401, P1404, P0405 D P1120, P1515, P1221, P1516, P1635 D P1275, P1639, P1271, P1273 D P1285, P1646, P1272, P1273 D P0336, P0337 D P0341, P0342 D P1220, P1515, P1221, P1515, P1516 D P1280, P1271, P1272 Check for the following conditions:...
  • Page 948 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–79 Multiple PCM Information Sensor DTCs Set Step Action Value(s) Go to OBD Was the “On-Board (OBD) System Check” performed? System Check — Go to Step 2 1. Turn the ignition “OFF,” disconnect the PCM. 2.
  • Page 949 6E–80 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Multiple PCM Information Sensor DTCs Set (Cont'd) Step Action Value(s) Locate and repair the short circuit in the MAP or EGR or Vapor Pressure sensor signal or GND circuit. Is the action complete? —...

  • Page 950: Exhaust Gas Recirculation (Egr) Diagnosis 6E-81

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–81 Exhaust Gas Recirculation (EGR) DESIRED IDLE — Tech 2 Range 0-3187 RPM — The idle speed that the PCM is commanding. The PCM Diagnosis will compensate for various engine loads based on engine An EGR flow check diagnosis of the linear EGR system is coolant temperature, to keep the engine at the desired covered by DTC P0401.
  • Page 951 6E–82 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS FUEL PUMP — Tech 2 Displays ON or OFF — HO2S WARM UP TIME BANK 1, SEN. 1/BANK 1, Indicates the PCM commanded state of the fuel pump SEN 2/BANK 2 SEN. 1/BANK 2 SEN. 2 — Tech 2 relay driver circuit.
  • Page 952 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–83 START-UP IAT — Tech 2 Range –40°C to 151°C — Tech 2 Range 10-105 kPa (0.00-4.97 Volts) — (–40°F to 304°F) — The manifold absolute pressure (MAP) sensor measures Indicates the intake air temperature at the time that the the change in the intake manifold pressure from engine vehicle was started.

  • Page 953: L V-6 Engine (Automatic And Manual Transmission)

    6E–84 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 3.5L V-6 Engine (Automatic and Manual Transmission) Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) A/C Clutch Engine On/Off General Description and Relay Operation, A/C Clutch Circuit Operation...
  • Page 954 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–85 Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) EGR Feedback Engine Volts 0.45-0.80 0.45-0.80 — Engine Percent — Normalized Engine Load Engine Percent 2.0% - 5.5% 8.0% - 16.0%...
  • Page 955 6E–86 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) HO2S Bank 1 O2 Sensor Ready Ready Ready General Description and Sen.1 Data Operation, Fuel Control Yes/No (ready/not HO2S;...
  • Page 956 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–87 Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) MAP kPa Engine Kilopascals 23-40 19-32 General Description and (Manifold Operation, Manifold Absolute Absolute Absolute Pressure (MAP) Absolute Pressure (MAP) Volts...
  • Page 957 6E–88 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) Start-Up IAT Engine Degrees C, Depends on Depends on General Description and (Intake Air Degrees F intake air intake air...

  • Page 958: No Malfunction Indicator Lamp (Mil)

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–89 No Malfunction Indicator Lamp (MIL) D06RY00127 Circuit Description Test Description Number(s) below refer to the step number(s) on the The “Check Engine” lamp (MIL) should always be Diagnostic Chart. illuminated and steady with the ignition “ON” and the engine stopped.
  • Page 959 6E–90 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS No Malfunction Indicator Lamp (MIL) Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 Attempt to start the engine. — Go to Step 3 Go to Step 6 Does the engine start?
  • Page 960 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–91 No Malfunction Indicator Lamp (MIL) (Cont'd) Step Action Value(s) Locate and repair the short to ground in the PCM ignition feed circuit or PCM battery feed circuit. Is the action complete? — Verify repair —...

  • Page 961: Malfunction Indicator Lamp (Mil) "On" Steady

    6E–92 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Malfunction Indicator Lamp (MIL) “ON” Steady D06RY00127 Circuit description Test Description Number(s) below refer to the step number(s) on the The malfunction indicator lamp (MIL) should always be Diagnostic Chart. illuminated and steady with ignition “ON” and the engine stopped.
  • Page 962 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–93 Malfunction Indicator Lamp (MIL) “ON” Steady Step Action Value(s) Go to OBD Was the “On-Board diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Ignition “OFF,” disconnect PCM. 2.

  • Page 963: No Reduced Power Lamp (Rpl)

    6E–94 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS No Reduced Power Lamp (RPL) D06RY00127 Circuit Description Test Description The Reduced Power lamp (RPL) should always be Number(s) below refer to the step number(s) on the illuminated and steady with the ignition “ON” and the Diagnostic Chart.
  • Page 964 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–95 No Reduced Power Lamp (RPL) Step Action Value(s) Go to OBD Was the “On - Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 Attempt to start the engine. —...
  • Page 965 6E–96 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS No Reduced Power Lamp (RPL) (Cont'd) Step Action Value(s) Locate and repair the short to ground in the PCM ignition feed circuit or PCM battery feed circuit. Is the action complete? — Verify repair —...

  • Page 966: Reduced Power Lamp (Rpl) "On" Steady

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–97 Reduced Power Lamp (RPL) “ON” Steady D06RY00127 Circuit Description Test Description The Reduced Power lamp (RPL) should always be Number(s) below refer to the step number(s) on the illuminated and steady with ignition “ON” and the engine Diagnostic Chart.
  • Page 967 6E–98 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Reduced Power Lamp (RPL) “ON” Steady Step Action Value(s) Go to OBD Was the “ On - Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Ignition “OFF,” disconnect PCM. 2.

  • Page 968: Engine Cranks But Will Not Run

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–99 Engine Cranks But Will Not Run D06RY00150...
  • Page 969 6E–100 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS D06RY00042...

  • Page 970: Circuit Description

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–101 Circuit Description Test Description The electronic Ignition system uses a coil -at-plug method Number(s) below refer to the step number(s) on the of spark distribution. In this type of ignition system, the Diagnostic Chart.
  • Page 971 6E–102 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) 1. Ignition “OFF”, install a fuel pressure gauge at the test fitting on the fuel supply line in the engine compartment. (Use a shop cloth to absorb any fuel leakage while making the connection.) 2.
  • Page 972 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–103 Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) 1. Ignition “ON.” 2. While the coil connectors are disconnected, touch each coil connector’s ignition feed terminal with a grounded test light (the ignition feed wire is black with orange tracer).
  • Page 973 6E–104 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) Refer to Engine Mechanical Diagnosis to diagnose the following conditions: Faulty or incorrect camshaft drive belts Leaking or sticky valves or rings Excessive valve deposits Loose or worn rocker arms Weak valve springs...
  • Page 974 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–105 Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) 1. At the injector (male) side of the gray connector mentioned in step 25, connect an ohmmeter between the ignition pin and one of the driver circuit pins.

  • Page 975: Fuel System Electrical Test

    6E–106 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Fuel System Electrical Test D06RY00150...

  • Page 976: Circuit Description

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–107 Circuit Description Fuel Pressure Relief Procedure When the ignition switch is first turned “ON,” the 1. Remove the fuel cap. powertrain control module (PCM) energizes the fuel 2. Remove the fuel pump relay from the underhood pump relay which applies power to the in-tank fuel pump.

  • Page 977: Check

    6E–108 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Fuel System Electrical Test Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Read the “Caution” above. 2. Relieve the fuel system pressure and install the fuel pump pressure gauge to the test fitting.
  • Page 978 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–109 Fuel System Electrical Test (Cont'd) Step Action Value(s) Replace the PCM. IMPORTANT: The replacement must Refer to On-Vehicle Service in programmed. Powertrain Control Module Sensors procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not.
  • Page 979 6E–110 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Electric Throttle Control (ETC) System Check D06RY00179...

  • Page 980: Circuit Description

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–111 Circuit Description Test Description D The powertrain control module (PCM) controls Number(s) below refer to the step number(s) on the Diagnostic Chart: engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC 2.
  • Page 981 6E–112 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Electric Throttle Control (ETC) System Check Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 Visually/physically inspect for the following conditions: Throttle body tampering.
  • Page 982 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–113 Electric Throttle Control (ETC) System Check (Cont'd) Step Action Value(s) 1. Install the Tech 2 Idle AP1 = 11–13% 2. Ignition “ON” but not engine run. AP2 = 87–88% 3. Chech the valve for APS and TPS. AP3 = 87–88% Was the prblem found? TP1 = 3–13%...

  • Page 983: Fuel System Diagnosis

    6E–114 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Fuel System Diagnosis 140RW020 Legend (8) Fuel Rail Left (1) Fuel Filler Cap (9) Left Bank (2) Fuel Tank (10) Fuel Pressure Control Valve (3) Rollover Valve (11) Common Chamber (4) Fuel Pump and Sender Assembly (12) Duty Solenoid Valve (5) Fuel Filter (13) Throttle Valve...

  • Page 984: Fuel Pressure Relief Procedure

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–115 D The valve or valve seat within the fuel pressure 20.This test determines if the high fuel pressure is due regulator. to a restricted fuel return line or if the high fuel pressure is due to a faulty fuel pressure regulator.
  • Page 985 6E–116 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Fuel System Diagnosis Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Turn the ignition “OFF.” 2. Turn the air conditioning system “OFF.” 3.
  • Page 986 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–117 Fuel System Diagnosis (Cont'd) Step Action Value(s) Locate and repair the loss of vacuum to the fuel pressure regulator. Is the action complete? — Verify repair — Replace the fuel pressure regulator. —...
  • Page 987 6E–118 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Fuel System Diagnosis (Cont'd) Step Action Value(s) Is the fuel pressure indicated by the fuel pressure 0 kPa (0 psi) Go to Step 22 Go to Step 23 gauge above the specified value? 1.

  • Page 988: Exhaust Gas Recirculation (Egr) System Check

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–119 Exhaust Gas Recirculation (EGR) System Check 060RY00167 Circuit Description Diagnostic Aids The EGR valve chart is a check of the EGR system. An A properly operation exhaust gas recirculation (EGR) EGR pintle constantly in the closed position could cause system will directly affect the air/fuel requirements of the detonation and high emissions of NOx.
  • Page 989 6E–120 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Exhaust Gas Recirculation (EGR) System Check Step Action Value(s) Check the EGR valve for looseness. Go to Step 2 Go to Step 3 Is the EGR valve Loose? — Tighten the EGR valve. Is the action complete? —...

  • Page 990: Manifold Absolute Pressure (Map) Output Check

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–121 Manifold Absolute Pressure (MAP) Output Check D06RY00165 Circuit Description Test Description The manifold absolute pressure (MAP) sensor measures IMPORTANT: Be sure to used the same diagnostic test the changes in the intake MAP which result from engine equipment for all measurements.
  • Page 991 6E–122 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Manifold Absolute Pressure (MAP) Output Check Step Action Value(s) 1. Turn the ignition “OFF”and leave it “OFF” for 15 seconds. 2. Ignition “ON.” Don’t crank engine. 3. The Tech 2 should indicate a manifold absolute pressure (MAP) sensor voltage.

  • Page 992: Evaporative (Evap) Emissions Canister Purge Valve Check

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–123 Evaporative (EVAP) Emissions Canister Purge Valve Check D06RY00128 Circuit Description Diagnostic Aids D Make a visual check of vacuum hoses. Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. D Check the throttle body for possible cracked.
  • Page 993 6E–124 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Evaporative (EVAP) Emissions Canister Purge Valve Check Step Action Value(s) 1. Ignition “OFF.” 2. Ignition “ON,” engine “OFF.” 3. At the throttle body, disconnect the hose that goes to the pump solenoid. 4.
  • Page 994 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–125 Evaporative (EVAP) Emissions Canister Purge Valve Check (Cont'd) Step Action Value(s) 1. Turn the ignition “OFF.” 2. At the throttle body, install a vacuum gauge where the hose from the purge solenoid was disconnected for testing.

  • Page 995: Upshift Lamp System Check (Manual Transmission Only)

    6E–126 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Upshift Lamp System Check (Manual Transmission Only) 060RY00127...

  • Page 996: Circuit Description

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–127 Circuit Description Inspect the PCM harness and connector for proper mating, broken locks, improperly formed or damaged The shift lamp indicates the best transmission shift point terminals, poor terminal-to-wire connection for maximum fuel economy. damaged harness.
  • Page 997 6E–128 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Up-Shift Lamp System Check (Cont'd) Step Action Value(s) 1. Replace the Clutch Switch. Or, 2. Repair for an open or short of WHT/GRN wiring harness. Is the action complete? Verify Repair — —...

  • Page 998: Pcm Diagnostic Trouble Codes

    TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–129 PCM Diagnostic Trouble Codes The following table lists the diagnostic trouble codes supported by this vehicle application. If any DTCs not listed here are displayed by a Tech 2, the Tech 2 data may be faulty;...
  • Page 999 6E–130 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Description Type Illuminate Illuminate (Check (Reduced Enigne Power Lamp) Lamp) P0175 O2 Sensor – System too Rich (Bank 2) P0201 Injector 1 Control Circuit P0202 Injector 2 Control Circuit P0203 Injector 3 Control Circuit P0204 Injector 4 Control Circuit P0205...
  • Page 1000 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–131 Description Type Illuminate Illuminate (Check (Reduced Enigne Power Lamp) Lamp) P0463 Fuel Level Sensor Circuit High Input Voltage P0502 No VSS Signal P0506 Idle Speed Control RPM too Low P0507 Idle Speed Control RPM too High P0562 System Voltge is Low P0563...

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