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Isuzu Trooper 1999 Workshop Manual

Isuzu Trooper 1999 Workshop Manual

Trooper 1999

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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 1999 models.

SECTION

TABLE OF CONTENTS

Click

General Information

0A

General Information

0B

Maintenance And Lubrication

HEATING, VENTILATION AND AIR CONDITIONING

1A

2A

Power Assisted System

3C

Front Suspension

3D

Rear Suspension

3E

Wheel And Tire System

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

6C

6D1

Engine Electrical

6D2

Ignition System

6D3

Starting And Charging System

6E

Driveability and Emissions

6F

6G

Engine Lubrication

6H

Engine Speed Control System

6J

7A

Automatic Transmission

7A1

Transmission Control System

7B

Manual Transmission

7C

Body And Accessories

8A

Lighting System

8B

Wiper/Washer System

8C

8D

8E

Meter And Gauge

8F

8G

8H

Security And Locks

8I

Sun Roof/Convertible Top

8J

Exterior/Interior Trim

9A

Seat Belt System

9J

Supplemental Restraint System (Srs)

9J1

Restraint Control System

CONTROL SYSTEM

10A

Cruise Control System

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Need help?

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Do you have a question about the Trooper 1999 and is the answer not in the manual?

Questions and answers

Brett

March 10, 2025

I have a new windshield wiper motor of just as few months. Now there is no pressure to eject the water to the windshield. I hear the motor working and a small amount of water is leaking out onto my hood on the backside of the water sprayers on the hood. I think it could be dirt-- Yes I have used needles to poke the holes to open it up. I think it might be clogged where the hose connects to the jets. How do I remove the hose to the jets== was afraid of breaking it IF I just pulled it off. Is there a connection issue that I need to know to disconnect it?

0

Summary of Contents for Isuzu Trooper 1999

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: General Information
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 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 f Ambient/Clean air flow Front of vehicle f Cool air flow f Gas other than ambient air Up Side f Hot air flow f Ambient air mixed...
Page 4: Vehicle Identification Number
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. 710RX001 F00RX007...
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 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 0A–10 GENERAL INFORMATION Lifting Instructions CAUTION: f 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. f 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 f When using a floor jack, lift on the center of the skid f 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 f Position the chassis stands at the bottom of the rear axle case. 420RS001...
Page 14 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 Identifica- tion Bolt Diameter Pitch (mm) M 6X1.0 4—8 (3—6) 5—10 N·m (4—7 lb ft) —...
Page 15 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 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: Maintenance And Lubrication
SECTION MAINTENANCE AND LUBRICATION 0B–1 TROOPER GENERAL INFORMATION MAINTENANCE AND LUBRICATION CONTENTS Maintenance Schedule List ....0B–1 Lubricant Viscosity Chart ....0B–8 Explanation of Complete Vehicle Recommended Liquid Gasket...
Page 18 MAINTENANCE AND LUBRICATION 0B–2 Mileage Only Items F00RX008...
Page 19 MAINTENANCE AND LUBRICATION 0B–3 Mileage/Months F00RX009...
Page 20 MAINTENANCE AND LUBRICATION 0B–4 Explanation of Complete Vehicle Tire Rotation Maintenance Schedule Rotate tires every 7,500 miles (12,000 km). Brief explanations of the services listed in the preceding Power Steering Fluid Replacement Maintenance Scheduled are presented below. Drain the power steering fluid and then refill the system to Replace all questionable parts and note any necessary the proper level with power steering fluid after every repairs as you perform these maintenance procedures.
Page 21 MAINTENANCE AND LUBRICATION 0B–5 Fluid Leak Check Maintain pressure as shown in the tire placard, which is located on the driver’s door lock pillar. Check for fuel, water, oil or other fluid leaks by looking at the surface beneath the vehicle after it has been parked Steering System Operation for a while.
Page 22 MAINTENANCE AND LUBRICATION 0B–6 Accelerator Linkage Lubrication Clutch Control Lubrication Lubricate the accelerator pedal fulcrum pin with chassis Lubricate the clutch pedal bushing, the clevis pin, and grease. pedal spring every 15,000 miles (24,000 km) or 6 months. If a squeaking noise arises from around the bushing or the Steering and Suspension Inspection clevis pin at the clutch pedal arm when the clutch pedal is depressed, lubricate them.
Page 23: Recommended Fluids And Lubricants
MAINTENANCE AND LUBRICATION 0B–7 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 24 MAINTENANCE AND LUBRICATION 0B–8 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 25 MAINTENANCE AND LUBRICATION 0B–9 Oil Viscosity Chart for Manual Transmission and Transfer Case B00RW002 Oil Viscosity Chart for Front Axle B00RW003...
Page 26 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 27 MAINTENANCE AND LUBRICATION 0B–11 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 28 MAINTENANCE AND LUBRICATION 0B–12 Maintenance Service Data Service Data and Specifications ENGINE Valve clearance (cold) Intake 0.28 0.05 mm Exhaust 0.3 0.05 mm Spark plug type K16PR-P11/PK16PR11/RC10PYP4 Spark plug gap 1.05 mm (0.04 in) CLUTCH Clutch pedal free play 5-15 mm (0.20-0.59 in) BRAKE Brake pedal free play 6-10 mm (0.24-0.39 in)
Page 29 SECTION HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–1 TROOPER HEATING, VENTILATION AND AIR CONDITIONING (HVAC) HVAC SYSTEMS CONTENTS Service Precaution ..... . 1A–2 Center Vent, Drive Side Vent and Associated Parts...
Page 30: 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 31 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–3 The air selector knob, with its different modes, also allows into the passenger compartment. When setting the lever you to select and maintain the most comfortable to “RECIRC” position, the circulation of air is restricted passenger compartment temperature.
Page 32: Control Lever Assembly
1A–4 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 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 33 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–5 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 34 1A–6 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 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 35 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–7 Wiring Diagram D01RS005...
Page 36 1A–8 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 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 37 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–9 D01RS004 Condition Possible cause Correction Blower motor does not run. — Refer to Chart A Blower motor does not run in certain — Refer to Chart B, C, D and E position (s). Blower motor does not stop at “OFF”...
Page 38 1A–10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 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 39 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–11 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 40 1A–12 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater & A/C Relay Fan switch Resistor terminals Resistance position with continuity 1. Disconnect the heater and the A/C relay (B-36). 2.4 m 1 — 2 f When removing the connector for relay, unfasten the tang lock of the connector by using a 0.90 m 2 —...
Page 41 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–13 2. Check for continuity between the heater and the A/C relay (B-36) terminals. 825RS002 Relay terminals with Condition continuity Normal 1 – 3 (Approx 85–105m) When battery voltage is 2 – 4 applied between 1 – 3...
Page 42: Heater Unit
1A–14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Unit Heater Unit and Associated Parts 860RT001 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 43 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–15 8. Remove evaporator assembly (A/C only). f Refer to Evaporator Assembly in this section. 9. Remove instrument panel center bracket. f Refer to Cross Beam Assembly in Body and Accessories section. 10. Remove rear heater duct. 11.
Page 44 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. f Refer to Heater Unit in this section.
Page 45 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 46: 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 47: 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 48: Blower Assembly
1A–20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Blower Assembly Blower Assembly and Associated Parts 873RT001 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 49 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. f Refer to Control Lever Assembly in this section. Blower Link Unit and / or Mode door Disassembled View 873RS001 Legend...
Page 50 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 51: Blower Motor
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–23 Blower Motor Blower Motor and Associated Parts 873RS004 Legend (4) Fan (1) Blower Motor (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 52 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 53 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 54 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 55 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–27 8. Remove attaching screws. f 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 56: Control Panel Illumination Bulb
1A–28 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 2. Connect the control cable at the “CIRC” position 2. Connect the control cable at the “DEFROST” of the link unit of the blower assembly and position of the mode control link of the heater secure it with the clip.
Page 57: 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 1.
Page 58: 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 59 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 60 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 61 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 62 1A–34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Electronic Thermostat Refrigerant Line The thermostat consists of the thermo sensor (2) and Restriction in the refrigerant line will be indicated by: thermostat unit (4) which functions electrically to reduce 1. Suction line — A restricted suction line will cause low the noises being generated while the system is in suction pressure at the compressor, low discharge operation.
Page 63 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 64 1A–36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Wiring Diagram D08RW254...
Page 65 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–37 D08RX003...
Page 66 1A–38 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D08RW256...
Page 67 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 68 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 69 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 70 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 71 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 72 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 73 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 74 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 75 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 76: General Repair Procedure
1A–48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) f Keep moisture and contaminants out of the system. Relay terminals with con- Condition When disconnecting or removing any lines or parts, tinuity use plugs or caps to close the fittings immediately. Normal 1 –...
Page 77 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 78 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 79 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–51 f SHOULD HFC-134A CONTACT YOUR EYE(S), 4. Replace the O-rings. f O-rings cannot be reused. Always replace with new CONSULT A DOCTOR IMMEDIATELY. f DO NOT RUB THE AFFECTED EYE(S). INSTEAD, ones. SPLASH QUANTITIES OF FRESH COLD WATER f Be sure to apply the specified compressor oil to the OVER THE AFFECTED AREA TO GRADUALLY new O-rings.
Page 80 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 81 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–53 f Direct charging with a weight scale charging station method 1. Make sure the evacuation process is correctly completed. 2. Connect the center hose of the manifold gauge to the weight scale. 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle.
Page 82 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 83: 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 f Refer to Refrigerant Recovery in this section. 1.
Page 84 1A–56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 4. Remove drive belt. 4. Connect magnetic clutch harness connector. f Move drive belt tensioner to loose side using wrench then remove drive belt. 850RW001 Legend (1) Crankshaft Pulley (2) Cooling Fun Pulley (3) Auto Tensioner (4) Generator (5) Air Conditioner Compressor...
Page 85: Condenser Assembly
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–57 Condenser Assembly Condenser Assembly and Associated Parts 875RW001 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 86 1A–58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) f 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 87: Pressure Switch
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–59 Pressure Switch Pressure Switch and Associated Parts 875RW005 Legend (2) Pressure Switch (1) Pressure Switch Connector (3) Radiator Grille Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. f Refer to “Refrigerant Recovery in this section. 3.
Page 88 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 89 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. f Use a back-up wrench when disconnecting and 2.
Page 90 1A–62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. Remove evaporator assembly. f 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 91 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 92: Refrigerant Line
1A–64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Line Refrigerant Line and Associated Parts 852RW001 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 93 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–65 f 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 94: 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 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.) Radiating area...
Page 95 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–67 Torque Specifications 852RW004 874RW006...
Page 96: General Description
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 97 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 98 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 99 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 100 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 101 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 102 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 103 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 104 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 105 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 106 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 107: 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 108 1A–80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) TOOL NO. ILLUSTRATION TOOL NAME J-34614 Shaft Seal Protector J-39893 Pressure Testing Connector...
Page 109: Table Of Contents
SECTION POWER ASSISTED SYSTEM 2A–1 TROOPER STEERING POWER ASSISTED SYSTEM CONTENTS Service Precaution ..... . 2A–2 Installation ......2A–38 General Description .
Page 110 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 111 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 112 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 113 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 114 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 115 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 116 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 117 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 118 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 119: 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 120: Fluid Level
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 121: 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 122 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 123 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 124 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 125 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 126 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 127 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 128: 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 129 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 130: 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 131 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 132: Inspection And Repair
2A–24 POWER ASSISTED SYSTEM 8. Remove ball-nut and valve housing assembly. Ball-nut Rotation 440RS005 440RS006 f 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 133 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 134 2A–26 POWER ASSISTED SYSTEM f Lock the sector shaft adjusting screw with the lock 6. Install sector shaft. f Tape the sector shaft serrations to protect the seal nut. ring from damage. Lock nut torque: 41 N·m (30 lb ft) f Align the center tooth of ball nut with that of the 10.
Page 135 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 136: 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 137 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 138: Power Steering Pump Disassembled View
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 139 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 140 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 141 POWER ASSISTED SYSTEM 2A–33 Main Data and Specifications General Specifications Oil pump Type Vane Operating ATF DEXRON –III fluid Torque Specifications E02RX005...
Page 142: 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 143 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 144: 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 145 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 146 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 147: 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 148 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 149: Steering Linkage And Associated Parts
POWER ASSISTED SYSTEM 2A–41 Steering Linkage and Associated Parts Main Data and Specifications Torque Specifications E03RS004...
Page 150 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 151: Srs Connectors
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 152 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 153: 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 154 2A–46 POWER ASSISTED SYSTEM f 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 155: 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 156 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 157 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 158: 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 159 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 160 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 161 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: f Never use the air bag assembly from another vehicle.
Page 162: 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 163 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 164 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 165: 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 166: Steering Column And Associated Parts
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 167 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 168 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 169 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 170 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 171 POWER ASSISTED SYSTEM 2A–63 CAUTION: f Never use the air bag assembly from another vehicle. Use only the air bag assembly for “UX”. f 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 172 2A–64 POWER ASSISTED SYSTEM Supplemental Restraint System Steering Wheel & Column and Associated Parts Main Data and Specifications Torque Specifications E03RW001...
Page 173 POWER ASSISTED SYSTEM 2A–65 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–29752 Steering wheel remover...
Page 174: Front Suspension
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 175 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 176 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 177 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 178 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 179: 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 180: 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 181 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 182 3C 9 FRONT SUSPENSION f Height control arm 3. Apply the setting marks(2) to the height control arm and torsion bar, then remove height control arm. f Adjust bolt f Rubber seat Installation 1. Apply grease to the serrated portions, then install torsion bar.
Page 183 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 184 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 185 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 186 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 187 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 188 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 189 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 190 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 191 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 192 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 193 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 194 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 195 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 196 3C 23 FRONT SUSPENSION f 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 197 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 198 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 199 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 200 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 201: 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 202 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 203 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 204 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: f Coil spring f Insulator Installation 1. Install coil spring and make sure that the coil spring is installed in the proper position.
Page 205 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 206 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 207 REAR SUSPENSION 3D–7 f 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 208 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 209 REAR SUSPENSION 3D–9 f 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 210 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 211 REAR SUSPENSION 3D–11 f 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 212 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 213 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 214 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 215 REAR SUSPENSION 3D–15 Torque Specifications E03RW006...
Page 216 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 217: Wheel And Tire 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 218 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 219 WHEEL AND TIRE SYSTEM 3E–3 Diagnosis 480RS001 Irregular and Premature Wear If the following conditions are noted, rotate the tires: f Front tire wear is different from rear. Irregular and/or premature wear has many causes. f Uneven wear exists across the tread of any tire. Some of them are incorrect inflation pressures, lack of tire f Left and right front tire wear is unequal.
Page 220 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 221 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 222 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 223 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 224 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 225 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 226: Tire Replacement
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 227 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 228 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 229 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 230 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 231 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 232 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 233 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 234 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 235 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 236 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 237 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 238 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 239 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 240 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 241 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 242 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 243 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 244 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 245 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 246 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 247 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 248 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 249 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 250 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 251 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 252 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 253 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 254 4A1–26 DIFFERENTIAL (FRONT) E04RW003...
Page 255 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 256 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 257 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 258 DIFFERENTIAL (REAR) 4A2–2 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 259 DIFFERENTIAL (REAR) 4A2–3 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 260 DIFFERENTIAL (REAR) 4A2–4 Axle Housing Axle Housing and Associated Parts 420RW001 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 261 DIFFERENTIAL (REAR) 4A2–5 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 262: Axle Shaft
DIFFERENTIAL (REAR) 4A2–6 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 263 DIFFERENTIAL (REAR) 4A2–7 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 264 DIFFERENTIAL (REAR) 4A2–8 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 265: Pinion Oil Seal
DIFFERENTIAL (REAR) 4A2–9 9. Fix the parking brake cable mounting bolt (Behind the 11. Install antilock brake system sensor. back plate). 12. Install brake disc. 10. Install parking brake assembly, refer to Parking 13. Install brake caliper, refer to Disk Brakes in Brake Brakes in Brake section.
Page 266 DIFFERENTIAL (REAR) 4A2–10 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 267 DIFFERENTIAL (REAR) 4A2–11 Differential Assembly Differential Assembly and Associated Parts 425RW044 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 268 DIFFERENTIAL (REAR) 4A2–12 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 269 DIFFERENTIAL (REAR) 4A2–13 Disassembled View 415RW002 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 270 DIFFERENTIAL (REAR) 4A2–14 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 271 DIFFERENTIAL (REAR) 4A2–15 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 272 DIFFERENTIAL (REAR) 4A2–16 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–8611–01 and grip J–8092. 425RW030 3. Clean the side bearing bores. Place discs and dial 425RW028 indicator on to arbor, and place tool into position in 2.
Page 273 DIFFERENTIAL (REAR) 4A2–17 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 274 DIFFERENTIAL (REAR) 4A2–18 8. Select the shim thickness using the chart; Pinion marking –1 –2 –3 Dial indicator reading (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) 0.024 0.027 0.025 0.027 0.028 0.026 0.027 0.028 0.029 0.027 0.027 0.028 0.029 0.030 0.028 0.027...
Page 275 DIFFERENTIAL (REAR) 4A2–19 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 276 DIFFERENTIAL (REAR) 4A2–20 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 277 DIFFERENTIAL (REAR) 4A2–21 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 278 DIFFERENTIAL (REAR) 4A2–22 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 279 DIFFERENTIAL (REAR) 4A2–23 Differential Cage Assembly Disassembled View 415RW010 Legend (5) Differential Shaft (1) Thrust Washer (for Pinion Gear) (6) Ring Gear (2) Pinion Mate Gear (7) Bolt (3) Thrust Washer(for Side Gear) (8) Differention Cage (4) Side Gear (9) Lock Pin...
Page 280 DIFFERENTIAL (REAR) 4A2–24 f Oil seal Disassembly Ring gear replacement: 1. Remove bolt. 1. The ring gear should always be replaced with the 2. Remove ring gear. drive pinion as a set. 3. Remove lock pin using a small drift. 2.
Page 281 DIFFERENTIAL (REAR) 4A2–25 2. Install the pinion mate gear with thrust washer by 6. Tighten the bolts in diagonal sequence as illustrated. engaging it with the side gears while turning both Torque: 177N·m (130lb ft) pinion mate gears simultaneously in the same direction.
Page 282 4A2–26 DIFFERENTIAL (REAR) Locking Differential Assembly Disassembled View 425RW027 Legend (7) Differential Plate Retainer (1) Thrust Washer–Differential Pinion Mate Gear (8) Lock Pin (2) Pinion Mate Gear (9) Differential Case (3) Dished Spacer (10) Ring Gear Bolts (4) Disc (11) Differential Shaft (5) Plate (12) Differential Side Gear (6) Ring Gear...
Page 283 DIFFERENTIAL (REAR) 4A2–27 4. Remove Differential shaft (2) using hammer and 6. Both pinion mate gear thrust washers using a shim punch. stock (1) of 0.51 mm (0.020 in.) or equivalent tool to push out washers. Place shop towel behind case to prevent differential shaft from dropping out of case.
Page 284 4A2–28 DIFFERENTIAL (REAR) f Differential Shaft. If excessive wear is evident, the 11. Remove top side gear and clutch pack. differential shaft should be replaced. NOTE: f Differential Plate Retainers. If wear is evident on any f Keep the stack of plates and discs intact and in one of the differential plate retainers, all four retainers exactly the same position while they are being must be replaced.
Page 285 DIFFERENTIAL (REAR) 4A2–29 8. Install pinion mate gears. 13. Install ring gear and tighten the bolts in diagonal f Place the pinion mate gears into the differential 180 sequence as illustrated. degrees apart. Torque: 177N·m (130lb ft) 9. While holding gears in place, insert differential shaft in NOTE: Discard used bolts and install new ones.
Page 286 4A2–30 DIFFERENTIAL (REAR) 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 287 DIFFERENTIAL (REAR) 4A2–31 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 288 4A2–32 DIFFERENTIAL (REAR) TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–8092 J–8001 Grip Dial indicator J–42831 J–42825 Installer; Inner bearing Disc (2 required) outer race J–42824 J–23597–1 Pilot;Outer Arbor J–21777–43 J–42828 Nut & Stud Installer; Pinion bearing J–42827 J–39209 Pilot;Inner...
Page 289 DIFFERENTIAL (REAR) 4A2–33 TOOL NO. ILLUSTRATION TOOL NAME 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...
Page 290 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 291 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 292 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 293 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 294 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 295 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 296 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 297 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 298 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–9 Wiring Diagram D08RW028...
Page 299 4B1–10 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) D08RW029...
Page 300 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–11 Connector List D04RW030...
Page 301 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 302 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 303 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 304 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 305 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 306 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–17 Front Axle Diagnosis f 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 307 4B1–18 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) f 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 308 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 309 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 310 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 311 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 312 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 313 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 314 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 315 4B2–2 DRIVE LINE CONTROL SYSTEM (TOD) General Description C07RW014 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 TOD SW Mode...
Page 316 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–3 detects the slip condition, determines the optimum torque based on the feedback control logic, and increases the torque to the front wheels. The control unit uses the signal from the throttle position sensor to predict the future vehicle condition and the intention of the driver with respect to acceleration and deceleration, and determines the initial torque distribution using these data and the information from the speed...
Page 317: System Components
4B2–4 DRIVE LINE CONTROL SYSTEM (TOD) System Components Parts Location A07RW020 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 318 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, 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 319 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 switches to reduction gear ratio is 1.000 and the corresponding the vehicle harness.
Page 320 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–7 Check Lamp Inform the following items. f Valve check f Fail (fail alarm) f Trouble code f Diesel/gasoline MAP 821RW078 TOD ECU This control unit is mounted to the front right hand seat via a special bracket.
Page 321 4B2–8 DRIVE LINE CONTROL SYSTEM (TOD) Functions of Indicator Lamp TOD Indicator Lamps C07RW018 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 322 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–9 C07RW015 Valve Check NOTE: Once the starter switch is turned on, all the TOD indicator lamps are lit for two seconds even if the transfer When the starter switch is turned on, the TOD indicator lever is in any position.
Page 323 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 324 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–11 The CHECK lamp also has the following functions. NOTE: If the TPS has failed, this function might not work. D-G MAP recognition and display (The control unit 1. When the control unit recognizes the vehicle as displays what type of vehicle, diesel or gasoline gasoline type, the CHECK lamp is turned on for five vehicle, it recognizes.)
Page 325 4B2–12 DRIVE LINE CONTROL SYSTEM (TOD) 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 326 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–13 f If no trouble codes exist, code “12” is displayed Indication Method of Trouble Code continuously. f Short-circuit terminal 8 of the self-diagnostic f 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 327 4B2–14 DRIVE LINE CONTROL SYSTEM (TOD) 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 328 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–15 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 fault diagnostic procedure.
Page 329 4B2–16 DRIVE LINE CONTROL SYSTEM (TOD) Basic Diagnostic Flow Chart C07RW023...
Page 330 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–17 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–5 (4) H–32, H–33 (15) E–30 (5) Fuse Box (16) Relay & Fuse Box (6) C–16 (17) H–12 (7) B–13 or B–14 (18) B–48, B–49...
Page 331: Circuit Diagram
4B2–18 DRIVE LINE CONTROL SYSTEM (TOD) Circuit Diagram D04RW021...
Page 332 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–19 D04RW022...
Page 333 4B2–20 DRIVE LINE CONTROL SYSTEM (TOD) D04RW023...
Page 334: Connector List
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–21 Connector List D04RW027...
Page 335 4B2–22 DRIVE LINE CONTROL SYSTEM (TOD) D04RW028...
Page 336 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–23 Checking Failed Pin Connector Pin Assignment f ECU pin assignment D04RW032...
Page 337 4B2–24 DRIVE LINE CONTROL SYSTEM (TOD) NAME CONTENTS Power supply (main) Not used 4WD OUT 4WD signal output SOL (+) Electromagnetic solenoid ADC (+) Axle disconnect output LIGHTING SW Lighting SW input BRAKE Brake SW input 4H SW 4H SW input 4L SW 4L SW input AXEL SW...
Page 338 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–25 Reference f Transfer connector pin assignment (connector on the transfer case) for inspection of transfer pins. 810RW006 NAME CONTENTS Ref. (Rer. ) Rear speed sensor reference output Ref. (Frt. ) Front speed sensor reference output SW GND SW GND 4H SW (+)
Page 339 4B2–26 DRIVE LINE CONTROL SYSTEM (TOD) 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 340 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–27 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 341 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 342 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–29 060RX062...
Page 343 4B2–30 DRIVE LINE CONTROL SYSTEM (TOD) 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 344 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–31 Fault Diagnosis from Trouble Codes f 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 345 4B2–32 DRIVE LINE CONTROL SYSTEM (TOD) 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. D04RW019...
Page 346 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–33 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 harness of terminal 24 (vehicle side terminal of Replace speed the front speed sensor)? sensor.
Page 347 4B2–34 DRIVE LINE CONTROL SYSTEM (TOD) 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) = 832 Hz (at 50 km/h) NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.
Page 348 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–35 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 harness of terminal 24 (vehicle side terminal of Replace speed the front speed sensor)?
Page 349 4B2–36 DRIVE LINE CONTROL SYSTEM (TOD) 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) = 832 Hz (at 50 km/h) NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.
Page 350 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–37 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 harness of terminal 23 (vehicle side terminal of Replace speed the rear speed sensor)?
Page 351 4B2–38 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard Rear 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. D04RW019...
Page 352 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–39 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 harness of terminal 23 (vehicle side terminal of Replace speed the rear speed sensor)? sensor.
Page 353 4B2–40 DRIVE LINE CONTROL SYSTEM (TOD) 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 354 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–41 Step Action 1. Start the engine. Does the voltage between terminals 15 and 19 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 355 4B2–42 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The voltage of the throttle position sensor (TPS) is faulty. The signal voltage from the TPS deviates from the stan- dard range. D04RW017...
Page 356 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 21 and 19 fall within the standard range above? Go to Step 6 Go to Step 3...
Page 357 4B2–44 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The diesel/gasoline engine identifi- Continuity established cation signal is faulty. The engine identification signals 6VE1 are changed each other. D04RW017...
Page 358 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–45 Step Action 1. Turn off the starter switch. The harness is broken. Repair Is the continuity established between terminals 14 and 19? the circuit. Go to Step 2 Go to Step 3 1. Turn on the starter switch. The phenomenon is not Does the voltage between terminals 14 and 19 indicate 0V?
Page 359 4B2–46 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The electromagnetic coil is broken. — D04RW016...
Page 360 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–47 Step Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the continuity established between terminals 4 and 20? Go to Step 2 Go to Step 4 1. Connect the ECU connector. 2.
Page 361 4B2–48 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) D04RW015...
Page 362 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–49 Step Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Does the resistance between terminals 4 and 20 indicate 1.0 to 5.0 ohm? Go to Step 2 Go to Step 3 1.
Page 363 4B2–50 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 CAUTION: If code 32 or 33 is also observed, remove between 2WD and 4WD modes normally.
Page 364 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–51 Step Action 1. Turn on the starter switch. 2. Set the transfer to the 2H mode. Is the battery voltage observed between terminals 5 and 19? Go to Step 2 Go to Step 5 Is the battery voltage observed between terminals 10 and 19? Go to Step 3 Go to Step 6...
Page 365 4B2–52 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 366 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–53 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 5 and 19? Go to Step 2 Go to Step 3 Does the voltage between terminals 5 and 19 indicate 0V? The battery is...
Page 367 4B2–54 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The ADC line is short-circuited to — GND. f The system enters into the fail-safe mode because of NOTE: fusing or system protection. f The on/off signal line of the shift on the fly system is short–circuited to GND.
Page 368 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–55 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 5 and 19 meet the Refer to standard, R = 21 4 ohms? “Troubles intermittently...
Page 369 4B2–56 DRIVE LINE CONTROL SYSTEM (TOD) Check flow Trouble code Phenomenon Standard The CHECK lamp indicator line is — short–circuited to the battery. The line is broken or short–circuited — to GND. D04RW013...
Page 370 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–57 Step Action 1. Turn on the starter switch. Is the CHECK lamp always turned on? Go to Step 2 Go to Step 3 1. Turn off the starter switch. The CHECK 2. Disconnect the ECU connector. circuit is 3.
Page 371 4B2–58 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. f After the starter is switched on, check and see if the status has become as tabulated below.
Page 372 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–59 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 373 4B2–60 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 1 and 19? circuit. the ECU. Go to Step 2 Go to Step 2 Check that all the parts are mounted.
Page 374 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–61 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 375 4B2–62 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Turn on the starter switch. Repair the 4WD SW circuit. When the 4WD SW is select to the 4WD position, is 0 V observed between terminal 12 and 19? Go to Step 2 Go to Step 4 When the 4WD SW is select to the 2WD position, is 12 V observed Repair the 4WD...
Page 376 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–63 Chart B–2 The 4WD 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 D04RW010...
Page 377 4B2–64 DRIVE LINE CONTROL SYSTEM (TOD) Step Action When the 4WD SW is select to the 4WD position, is 0 V observed Repair the 4WD between terminal 12 and 19 (4H switch)? SW circuit. Go to Step 7 Go to Step 2 When the 4WD SW is select to the 2WD position, is 12 V observed Repair the 4WD between terminals 12 and 19 (4H switch)?
Page 378 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–65 Chart C–1 4H switch circuit wires are broken or the battery is short-circuited. Function of circuit — Fail condition When the 4WD SW 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 379 4B2–66 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 8 and 19 (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 380 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–67 Chart C–2 The 4H switch circuit is short-circuited to GND. Function of circuit — Fail condition When the transfer lever is shifted from 4L, the indicator lamp status is not changed. Indicator lamp status Transfer position D04RW007...
Page 381 4B2–68 DRIVE LINE CONTROL SYSTEM (TOD) Step Action When the transfer lever is shifted to the High position, is 5V observed between terminals 8 and 19 (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 8 and 19 (4H switch)? Go to Step 3 Go to Step 14...
Page 382 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–69 Step Action When the transfer lever is shifted to the high position, is the continuity established between terminals 8 and 19? Go to Step 17 Go to Step 16 When the transfer lever is shifted to the 4L position, is the The ECU has continuity established between terminals 8 and 19? failed.
Page 383 4B2–70 DRIVE LINE CONTROL SYSTEM (TOD) 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 384 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–71 Step Action Turn on the starter switch. When the transfer lever is shifted to the high position, is 5V observed between terminals 9 and 19 (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 385 4B2–72 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 D04RW006...
Page 386 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–73 Step Action When the transfer lever is shifted to the high position, is 5V observed between terminals 9 and 19 (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 9 and 19 (4L switch)? Go to Step 3 Go to Step 7...
Page 387 4B2–74 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 388 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–75 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 D04RW005...
Page 389 4B2–76 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 10 and 19? Go to Step 2 Go to Step 7 When the transfer lever is shifted to the high position and 4WD switch shifted to 4WD position, is 0V observed between terminals 10 and 19?
Page 390 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–77 Step Action When the transfer lever is shifted to the high position and 4WD Repair the circuit switch shifted to 4WD position, is 0V observed on each VSV? of replace the 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 391 4B2–78 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 SW is select to the 2WD position, the 2WD mode is not enabled. (The transition status is not removed.) Indicator lamp status Transfer position D04RW005...
Page 392 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–79 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 10 and 19? Go to Step 2 Go to Step 7 When the transfer lever is shifted to the high position and 4WD switch shifted to 4WD position, is 0V observed between terminals 10 and 19?
Page 393 4B2–80 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 394 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–81 Chart G The trouble codes are displayed. Function of circuit — Fail condition Indicator lamp status Transfer position — D04RW004...
Page 395 4B2–82 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Disconnect the ECU connector from ECU. The ECU has failed. Replace Is the continuity established between terminals 13 and 19? the ECU. Go to Step 2 Go to Step 3 Is the self-diagnostic connector short-circuited? Open the self-diagnostic connector.
Page 396 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–83 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 397 4B2–84 DRIVE LINE CONTROL SYSTEM (TOD) Step Action 1. Disconnect ECU terminal. Wirers are broken 2. Turn on the starter switch. lighting SW circuit. Repair Is battery voltage observed between ECU terminals 6 and 19? the circuit. Go to Step 2 Go to Step 4 Turn lighting SW “ON”.
Page 398 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–85 Fault Diagnosis from Symptom Troubles that are not indicated by the warning lamp are cross-check the reported trouble with the listed listed in the table below. These troubles are caused by phenomena, and diagnose and analyze the trouble on the the faults that cannot be detected by the self-diagnostic item by item basis.
Page 399 4B2–86 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 400 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–87 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 401 4B2–88 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 4 and 20 range between 0.1 and 1.0V? Go to Step 16 Go to Step 16...
Page 402 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–89 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. D04RW002...
Page 403 4B2–90 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Is the trouble code 31 or 26 recorded? Examine the trouble based on “Fault 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 “Fault Diagnosis...
Page 404 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–91 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 405 4B2–92 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Do the indicator lamps show the correct status? Examine the trouble based on “Fault 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 “Fault Diagnosis...
Page 406 DRIVE LINE CONTROL SYSTEM (TOD) 4B2–93 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. D04RW020...
Page 407 4B2–94 DRIVE LINE CONTROL SYSTEM (TOD) Step Action Are the brake and ABS systems healthy? Repair the brake and ABS. Go to Step 4 Go to Step 2 Turn on the starter switch. Repair the battery system. Is the battery voltage observed between terminals 1 and 20? Go to Step 4 Go to Step 3 1.
Page 408: Drive Shaft System
Front Propeller Shaft in this section. 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 409 4C–2 DRIVE SHAFT SYSTEM 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 410 DRIVE SHAFT SYSTEM 4C–3 Front Hub and Disc 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 411 4C–4 DRIVE SHAFT SYSTEM f 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 412 DRIVE SHAFT SYSTEM 4C–5 Reassembly 3. Use installer J–36829 and grip J–8092, then install the inner bearing by driving it into the hub. 1. Install wheel pin. f Place the hub on a wood workbench or a block of wood approx. 6” by 6” to protect the wheel stud ends and threads.
Page 413 4C–6 DRIVE SHAFT SYSTEM 5. Apply grease (NLGI No.2 or equivalent) to the lip 8. Install hub nut. Turn to the place where there is a portion, then install oil seal by using installer J–36830 chamfer in the tapped hole to the outer side, then and grip J–8092.
Page 414 DRIVE SHAFT SYSTEM 4C–7 9. Install lock washer and lock screw in the following 12. Install hub cap. manner. 13. Tighten the bolts to the specified torque. f 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 415 4C–8 DRIVE SHAFT SYSTEM Main Data and Specifications Torque Specifications E04RW001...
Page 416 DRIVE SHAFT SYSTEM 4C–9 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 417 4C–10 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 f Refer to Front Drive Axle Assembly Replacement in grade.
Page 418 DRIVE SHAFT SYSTEM 4C–11 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 419 4C–12 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 420 DRIVE SHAFT SYSTEM 4C–13 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 421 4C–14 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 422 DRIVE SHAFT SYSTEM 4C–15 17. Install the circlip (1) so that open ends are positioned 18. Install bellows. Adjust the air pressure within the away from the ball groove. bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure. 412RS019 412RS021 19.
Page 423 4C–16 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 424 DRIVE SHAFT SYSTEM 4C–17 7. Remove snap ring from front axle case by using snap 10. Remove inner shaft bearing by using a remover ring pliers. J–37452 and press. NOTE: Be careful not to damage the shaft. 412RW017 8. Take out inner shaft from front axle case. 412RW015 9.
Page 425 4C–18 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 426 DRIVE SHAFT SYSTEM 4C–19 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 427 4C–20 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 428 DRIVE SHAFT SYSTEM 4C–21 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 429 4C–22 DRIVE SHAFT SYSTEM 6. Install snap ring (internal) in the groove of front axle 12. Apply liquid gasket to the contact surface on the case. actuator side. NOTE: Be sure to install the snap ring properly. 412RW012 13. Align shift arm with the groove of sleeve and install the actuator.
Page 430 DRIVE SHAFT SYSTEM 4C–23 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 431 4C–24 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 432 DRIVE SHAFT SYSTEM 4C–25 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 433 4C–26 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 434 DRIVE SHAFT SYSTEM 4C–27 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 435 4C–28 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 436 DRIVE SHAFT SYSTEM 4C–29 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 437 4C–30 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 438 DRIVE SHAFT SYSTEM 4C–31 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 439 4C–32 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 440 DRIVE SHAFT SYSTEM 4C–33 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 441 4C–34 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 442 DRIVE SHAFT SYSTEM 4C–35 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 443 4C–36 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 444 DRIVE SHAFT SYSTEM 4C–37 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 445 4C–38 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 446 DRIVE SHAFT SYSTEM 4C–39 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 447 4C–40 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 448 DRIVE SHAFT SYSTEM 4C–41 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 449 4C–42 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 450 DRIVE SHAFT SYSTEM 4C–43 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 451 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 452 4D1–2 TRANSFER CASE (STANDARD TYPE) General Description M/T model A07RW019...
Page 453 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 454 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 455: 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 456 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 457 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 458 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 459 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 460 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 461 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 462 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 f Remove the oil seal from the transfer rear case.
Page 463 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 464 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 465 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 466 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 467 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 468 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 469 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 470 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 471 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. f Springs (1) 38. Remove snap ring, use a pair of snap ring pliers to f Inserts (2) remove the snap ring.
Page 472 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 473 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 474 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 475 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 476 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 477 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 478 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 479 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 480 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 481 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 482 4D1–32 TRANSFER CASE (STANDARD TYPE) E07RW009...
Page 483 TRANSFER CASE (STANDARD TYPE) 4D1–33 E07RW010...
Page 484 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 485 TRANSFER CASE (STANDARD TYPE) 4D1–35 PART NO. ILLUSTRATION PART NAME J–37487 Puller J–8092 Driver handle...
Page 486 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 487 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 488 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 489 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 490 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 491 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 492 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 493 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 494: 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 495 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 496 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 497 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 498 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 499 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 500 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 501 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 502 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 503 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 504 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 505 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 506 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 507 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 508 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 509 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 510 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 511 4D2–26 TRANSFER CASE (TOD) f 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 512 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 513 4D2–28 TRANSFER CASE (TOD) Tension of Lock-up Fork Spring Multi Plate Disk Clutch f If the measurement exceeds the limit, replace the f 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 514 TRANSFER CASE (TOD) 4D2–29 Cam Pulley, Cam Ball, and Cam&Coil Housing f 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 515 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 516 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. f Identify the correct direction of gear. f Do not damage the gear.
Page 517 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 518 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 519 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 520 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 521 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 522 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 523 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 524 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 525 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 526 TRANSFER CASE (TOD) 4D2–41 E07RW012...
Page 527 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 528: Brake Control System
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 529 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 530: Electronic Hydraulic Control Unit (Ehcu)
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 531: 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 532: Abs Service Precautions
BRAKE CONTROL SYSTEM 5A–5 f 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 f The EHCU and valve block connectors should never be connected or disconnected with the ignition “ON”...
Page 533: 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 534: 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 535 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 536 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 537 5A–10 BRAKE CONTROL SYSTEM 060RX064...
Page 538: 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 539: Ehcu Connector Pin-Out Checks
5A–12 BRAKE CONTROL SYSTEM EHCU Connector Pin-out Checks f Disconnect Electronic Brake Control Module. f 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 540 BRAKE CONTROL SYSTEM 5A–13 Circuit Diagram D08RW033...
Page 541 5A–14 BRAKE CONTROL SYSTEM D08RW034...
Page 542 BRAKE CONTROL SYSTEM 5A–15 D08RW035...
Page 543 5A–16 BRAKE CONTROL SYSTEM Connector List D05RW002...
Page 544 BRAKE CONTROL SYSTEM 5A–17 D05RW003...
Page 545: 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 546: 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 547 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 548: Chart A-3, Ta-3 The Wheels Are Locked
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 549 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 550 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 551: Diagnostic Trouble Codes (Dtcs)
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 552 BRAKE CONTROL SYSTEM 5A–25 The DLC is located behind the driver side kick panel 350RT001 f 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 553 5A–26 BRAKE CONTROL SYSTEM 4. Notes f 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 554: Chart B-2 Ehcu Abnormality (Dtc)
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 555: Chart B-3 Power Voltage Drop (Dtc)
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 556 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 557: Chart B-7 Transfer Monitor (Dtc)
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 558 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 559 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 560 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 561 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 562 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 563 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 564 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 565 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 566 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 567 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 568: Unit 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 569 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 570 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 571 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 572 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 573 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 574 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 575 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 576 ANTI–LOCK BRAKE SYSTEM 5B–3 G-Sensor Removal Installation 1. Install G-sensor assembly (3). f Care should be taken so that the G-sensor is not installed in the wrong direction. 2. Install G-sensor assembly fixing bolt (2). f Tighten the fixing bolt to the specified torque. Torque : 10 N·m (87 lb in) 3.
Page 577 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 578 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 579 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 580: Table Of Contents
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 581 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 582 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 583 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 584 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 585 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 586 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 587 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 588: 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 589: 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 590: 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 591: 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 592: 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 593: 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 594 POWER ASSISTED BRAKE SYSTEM 5C–15 Main Data and Specifications Torque Specifications E05RW001...
Page 595: 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 310RW002 NOTE: While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal.
Page 596: Brake Pedal And Associated Parts
POWER ASSISTED BRAKE SYSTEM 5C–17 Brake Pedal and Associated Parts 310RW003 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 597: 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 598 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 599: 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 600: 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 601 5C–22 POWER ASSISTED BRAKE SYSTEM Ä O–ring There should be a pressure increase of 0.5 kg/cmÂ 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 602 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 603 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 604: 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 605 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 must be replaced.
Page 606 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 607: 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 608: Vacuum Booster Overhaul
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 609 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 610 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 611: 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 612 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. f Draw out two–thirds of the brake fluid from the reservoir.
Page 613 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 614: 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 615 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 616: 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 617 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 618 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 619: 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 620 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 621 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 622 POWER ASSISTED BRAKE SYSTEM 5C–43 Main Data and Specifications General Specifications Type Floating, pin slide Pad dimension 55 cmÂ (8.52 inÂ ) 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...
Page 623 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 624 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. f Draw out two–thirds of the brake fluid from the reservoir.
Page 625 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 626 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 627 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 628 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 629 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 630 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 631 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 632 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 633 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 634 POWER ASSISTED BRAKE SYSTEM 5C–55 Main Data and Specifications General Specifications Type Floating, pin slide Pad dimension 33 cmÂ (5.11 inÂ ) 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...
Page 635: 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 636 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 637 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 638 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 639 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 640 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 641: Parking Brake Adjustment
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 642 5D–8 PARKING BRAKE Main Data and Specifications General Specifications Rear parking brake Type Duo–servo Lining Dimension 121.2 cmÂ (18.79 inÂ ) 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 643: Engine Mechanical
ENGINE MECHANICAL 6A–1 TROOPER ENGINE CONTENTS Engine Mechanical ..... . Driveability and Emissions ....Engine Cooling .
Page 644 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 645 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 646 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 647 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 648 6A–6 ENGINE MECHANICAL Rough Engine Idling or Engine Stalling Condition Possible cause Correction Trouble in fuel injection system Idle air control valve defective Replace 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...
Page 649 ENGINE MECHANICAL 6A–7 Condition Possible cause Correction Others Engine lacks compression Refer to “Hard Start” Valve incorrectly seated Lap valve Air Cleaner Filter clogged Replace filter element Valve timing incorrect Readjust Idle air control valve broken Replace Fast idle solenoid defective Replace Positive Crankcase Ventilation valve Replace...
Page 650 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 Excessive play in accelerator linkage Adjust or replace Mass Airflow Sensor circuit open or Correct or replace poor connections Mass Airflow Sensor defective...
Page 651 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 652 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 653 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 654 6A–12 ENGINE MECHANICAL Condition Possible cause Correction Noise from connecting rods or from Bearing or crankshaft pin worn Replace connecting rod bearings connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing (Faulty connecting rods connecting rod bearings usually Crankpin out of round Replace connecting rod bearings make an abnormal noise slightly...
Page 655 ENGINE MECHANICAL 6A–13 Condition Possible cause Correction Engine knocking Preignition due to use of spark plugs Install Spark Plugs of adequate heat of inadequate heat range range Carbon deposits in combustion Clean chambers Fuel too low in octane rating Replace fuel Wide Open Throttle enrichment Refer to Section 6E system failure...
Page 656 6A–14 ENGINE MECHANICAL Condition Possible cause Correction Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace Heated Oxygen Sensor defective Replace Signal vacuum hose loosely fitted or Correct or replace defective EGR Valve circuit open or shorted Correct or replace Exhaust Gas Recirculation Valve Replace...
Page 657 ENGINE MECHANICAL 6A–15 Condition Possible cause Correction leaking into combustion Valve stem oil seal defective Replace chambers due to poor seal in valve chambers due to oor seal in valve Valve stem or valve guide worn Replace valve and valve guide system leaking into...
Page 658 6A–16 ENGINE MECHANICAL Lubrication Problems Condition Possible cause Correction Oil pressure too low Wrong oil in use Replace with correct engine oil Relief valve sticking Replace Oil pump not operating properly Correct or replace Oil pump strainer clogged Clean or replace strainer Oil pump worn Replace Oil pressure gauge defective...
Page 659 ENGINE MECHANICAL 6A–17 Malfunction Indicator Lamp The instrument panel “CHECK ENGINE” Malfunction In- when the system checks the starting of engine, or senses dicator Lamp (MIL) illuminates by self diagnostic system malfunctions. Condition Possible cause Correction “CHECK ENGINE” MIL does not Bulb defective Replace illuminate at the starting of engine...
Page 660 6A–18 ENGINE MECHANICAL Cylinder Head Cover LH Removal 5. Disconnect following wiring connectors and bonding cable: 1. Disconnect battery ground cable. Â Manifold Absolute Pressure (MAP) sensor 2. Drain engine coolant from faucet bottom of radiator. Â Vacuum Switching Valve (VSV) for Induction Air 3.
Page 661 ENGINE MECHANICAL 6A–19 Â The cylinder head cover must be installed within 5 Legend minutes after sealant application to prevent (1) Crankshaft Pulley premature hardening of sealant. (2) Generator (3) Auto Tensioner (4) Idle Pulley (5) Cooling Fan Pulley (6) Power Steering Oil Pump (7) Drive Belt (8) Air Conditioner Compressor 12.
Page 662 6A–20 ENGINE MECHANICAL 5. Install auto tensioner assembly and tighten the fixing bolts to the specified torque. Torque : Shorter Bolt : 20 N·m (14.8 lb ft) Longer Bolt : 39 N·m (28.8 lb ft) 6. Install idle pulley and bracket assembly and tighten the fixing bolt to the specified torque.
Page 663 ENGINE MECHANICAL 6A–21 Cylinder Head Cover RH Removal NOTE: Disconnect the mass air flow (MAF) sensor connector, intake air temperature (IAT) sensor connector, 1. Disconnect battery ground cable. and positive crankcase ventilation (PCV) hose before hand the air cleaner duct assembly is removed. 2.
Page 664 6A–22 ENGINE MECHANICAL 16. Reomve timing belt covers for right bank side. 17. Remove ignition coil assemblies for the right side bank. 014RW143 Â Tighten bolts in turn to the specified torque. Torque : 8.8 N·m (77.9 lb in) 060RW001 Legend (1) Ignition Coil Connectors (2) Bolts...
Page 665 ENGINE MECHANICAL 6A–23 6. Install idle pulley assembly and tighten the fixing bolt to the specified torque. Torque : 52 N·m (38.4 lb ft) 7. Install fan pulley and bracket assembly and tighten the fixing bolts and nut to the specified torque. Torque : 22 N·m (16.2 lb ft) 8.
Page 666 6A–24 ENGINE MECHANICAL Common Chamber Removal 1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 025RW001 Legend (1) Common Chamber (2) Throttle Valve Assembly (3) Bolt 130RW001 Legend (1) Positive Crankcase Ventilation Hose Connector Installation (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly 1.
Page 667 ENGINE MECHANICAL 6A–25 3. Tighten adjusting nut and lock nut temporarily. 4. Loosen adjusting nut by three turns (2∼3.5mm 0.08∼0.14in) and tighten lock nut. Then manually operating the throttle valve, make sure that the valve lever returns up to the stopper screw.
Page 668 6A–26 ENGINE MECHANICAL Exhaust Manifold LH Removal 5. Remove heat protector two fixing bolts then the heat protector. 1. Disconnect battery ground cable. 6. Remove a bolt on engine LH side for air conditioner 2. Remove air cleaner duct assembly. (A/C) compressor bracket and loosen two bolts for A/C compressor then move A/C compressor to front side.
Page 669 ENGINE MECHANICAL 6A–27 Exhaust Manifold RH Removal 1. Disconnect battery ground cable. 2. Remove torsion bar. Refer to removal procedure in Front Suspension section. 3. Remove exhaust front pipe three stud nuts and two nuts then disconnect exhaust front pipe. 056RW001 Legend (1) Exhaust Gas Recirculation (EGR) Valve...
Page 670: Crankshaft Pulley
6A–28 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 130RW001 Legend (2) Cooling Fan Pulley (1) Positive Crankcase Ventilation Hose Connector (3) Tensioner (2) Intake Air Temperature Sensor...
Page 671: Timing Belt
ENGINE MECHANICAL 6A–29 Timing Belt Removal CAUTION: The pusher prevents air from entering the oil chamber. Its rod must always be facing 1. Disconnect battery ground cable. upward. 2. Remove air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. 4.
Page 672 6A–30 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 673 ENGINE MECHANICAL 6A–31 5. Install crankshaft pulley temporarily and tighten Legend center bolt by hand (do not use a wrench). (1) Alignment Mark on Camshaft Drive Gear Pulley Turn the crankshaft pulley clockwise to give some belt slack between the crankshaft timing pulley (2) Alignment Mark on Cylinder Head Cover.
Page 674 6A–32 ENGINE MECHANICAL 3. Install timing belt cover. 4. Install crankshaft pulley using J-8614-01, hold the crankshaft pulley and tighten center bolt to the Remove crankshaft pulley that was installed in step specified torque. 1 item 5. Tighten bolts to the specified torque. Torque : 167 N·m (123 lb ft) 5.
Page 675 ENGINE MECHANICAL 6A–33 Camshaft Removal 1. Disconnect battery ground cable. 2. Remove crankshaft pulley. Â Refer to removal procedure for Crankshaft Pulley in this manual. 3. Remove timing belt. Â Refer to removal procedure for Timing Belt in this manual. 4.
Page 676 6A–34 ENGINE MECHANICAL 014RW023 014RW041 4. Install camshaft assembly and camshaft brackets, Legend tighten twenty bolts on one side bank to the specified (1) Right Bank Camshaft Drive Gear 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 bracket.
Page 677 ENGINE MECHANICAL 6A–35 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 8. Install crankshaft pulley. side bank as shown in the illustration.
Page 678 6A–36 ENGINE MECHANICAL 4. Loosen adjusting nut by three turns (2∼3.5mm 0.08∼0.14in) and tighten lock nut. Then, manually operating the throttle valve, make sure that the valve lever returns up to the stopper screw. If it does not reach the stopper screw, repeat from step 1.
Page 679: Cylinder Head
ENGINE MECHANICAL 6A–37 Cylinder Head Removal NOTE: There is discrimination mark “R” for right bank and “L” for left bank on the cylinder head gasket as shown 1. Remove engine hood. in the illustration. 2. Disconnect battery ground cable. Do not reuse cylinder head gasket. 3.
Page 680 6A–38 ENGINE MECHANICAL 2. Install common chamber. Â Refer to installation procedure for Common Chamber in this manual. 3. Install cylinder head cover RH. Â Refer to installation procedure for Cylinder Head Cover RH in this manual. 4. Install cylinder head cover LH. Â...
Page 681 ENGINE MECHANICAL 6A–39 Valve Stem Oil Controller , Valve Spring and Valve Guide Removal 1. Disconnect battery ground cable. 2. Drain engine oil. Â Drain engine coolant. 3. Remove cylinder head assembly. Â Refer to removal procedure for Cylinder Head in this manual.
Page 682 6A–40 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 683 ENGINE MECHANICAL 6A–41 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 684 6A–42 ENGINE MECHANICAL Crankshaft and Main Bearings Removal F06RW010 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 685 ENGINE MECHANICAL 6A–43 6. Remove oil pump assembly. f 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. f Refer to removal procedure for Rear Oil Seal in this manual.
Page 686 6A–44 ENGINE MECHANICAL f The oil seal retainer must be installed within 5 f 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 f Clean contact surface of oil gallery and main (1) Around Bolt Holes...
Page 687 ENGINE MECHANICAL 6A–45 f Apply sealant (TB1207B or equivalent) to the oil 11. Install crankcase. pump mounting surface. f Remove oil on crankcase mounting surface and dry f The oil pump assembly must be installed within 5 the surface. f Properly apply a 4.5 mm (0.7 in) wide bead of minutes after sealant application before the sealant hardens.
Page 688 6A–46 ENGINE MECHANICAL f Tighten fixing bolts to the specified torque. Torque : 25 N·m (18 lb ft) 013RW003 013RW002 13. Install timing belt. f Refer to installation procedure for Timing Belt in this manual. 14. Install engine assembly. f Refer to installation procedure for Engine in this manual.
Page 689: Rear Oil Seal
ENGINE MECHANICAL 6A–47 Rear Oil Seal Removal 1. Remove transmission assembly. f 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 690: Engine Assembly
6A–48 ENGINE MECHANICAL Engine Assembly Removal 035RW027 1. Disconnect battery ground and positive cable. 23. Remove power steering pump fixing bolts, then power steering pump. Place the power steering pump 2. Remove battery. along with piping on the body side. 3.
Page 691 ENGINE MECHANICAL 6A–49 If the engine is assembled in the condition that the dowels have not been mounted in the specified posi- tions, the transmission may be damaged the trans- mission. 035RW005 Legend (1) Exhaust Front Pipe RH (2) O Sensor 012RS009 1.
Page 692 6A–50 ENGINE MECHANICAL 9. Install air conditioner compressor to engine and 19. Reconnect ground cable between engine and tighten to the specified torque. chassis. 6VE1 20. Reconnect harness connector to transmission and install transmission harness bracket on engine left Torque : side.
Page 693 ENGINE MECHANICAL 6A–51 If it does not reach the stopper screw, repeat from step 1. 035RW004 Legend (1) Clearance (2) Lock Nut (3) Adjusting Nut...
Page 694 6A–52 ENGINE MECHANICAL 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 Bracket Fixing Bolt...
Page 695 ENGINE MECHANICAL 6A–53 2. Remove camshaft bracket fixing bolt (5), camshaft 3. Cylinder head deck for corrosion, sand particles in bracket (6), then camshaft exhaust (7), and intake head and porosity. side (8). CAUTION: 3. Remove tappet with shim (11). Â...
Page 696 6A–54 ENGINE MECHANICAL 2. Tighten the M5 bolt to a suitable torque to prevent Legend the sub gear from moving . (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discrimination Mark LI: Left Bank Intake RI: Right Bank Intake...
Page 697 ENGINE MECHANICAL 6A–55 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 698 6A–56 ENGINE MECHANICAL 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 Bracket Fixing Bolts (8) Valve Spring (2) Camshaft Assembly Inlet (9) Oil Controller (3) Camshaft Assembly Exhaust (10) Spring Lower Seat (4) Shim...
Page 699 ENGINE MECHANICAL 6A–57 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 700 6A–58 ENGINE MECHANICAL 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 701 ENGINE MECHANICAL 6A–59 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 702 6A–60 ENGINE MECHANICAL 6. Check that the valve contact width is correct. 7. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the 7. Check that the valve seat insert surface is in contact contact width, and the depression.
Page 703 ENGINE MECHANICAL 6A–61 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 704 6A–62 ENGINE MECHANICAL 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 705 ENGINE MECHANICAL 6A–63 Camshaft Camshaft and Associated Parts 014RW040 Legend (6) Camshaft Drive Gear Pulley (1) Camshaft Bracket Fixing Bolt (7) Retainer Fixing Bolt (2) Camshaft Bracket (8) Retainer (3) Camshaft Assembly Intake (9) Camshaft Drive Gear (4) Camshaft Assembly Exhaust (10) Oil Seal (5) Pulley Fixing Bolt Disassembly...
Page 706 6A–64 ENGINE MECHANICAL 014RW060 014RW043 2. Remove twenty fixing bolts from inlet and exhaust 2. Use a micrometer to measure the diameter and the camshaft bracket on one side bank, then camshaft uneven wear of the camshaft journals. brackets (2). Replace the camshaft if the diameter or the uneven wear exceeds the specified limit.
Page 707 ENGINE MECHANICAL 6A–65 Runout Limit : 0.1 mm (0.0039 in) 014RW037 5. Replace the cylinder head and/or camshaft if the measured oil clearance exceeds the specified limit. 014RW044 1. Carefully clean the camshaft journal, the 4. Measure the camshaft journal oil clearance. camshaft bracket, and the cylinder head.
Page 708 6A–66 ENGINE MECHANICAL Limit : 0.12 mm (0.0047 mm) 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).
Page 709 ENGINE MECHANICAL 6A–67 Legend (1) Right Bank Camshaft Drive Gear (2) Left Bank Camshaft Drive Gear (3) Timing Mark on Drive Gear (4) Dowel Pin 014RW023 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.
Page 710 6A–68 ENGINE MECHANICAL 014RW031 014RW060 4. If the oil seal requires replacement, use the J–42985 to install the oil seal. 014RW034 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)
Page 711 ENGINE MECHANICAL 6A–69 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 712 6A–70 ENGINE MECHANICAL 7. Remove oil gallery (7). 8. Remove piston and connecting rod assembly (8). Refer to “Piston, Piston Ring and Connecting Rod” in this manual. 9. Remove flywheel (9). 10. Remove rear oil seal retainer (10). 11. Remove main bearing cap (11). 12.
Page 713 ENGINE MECHANICAL 6A–71 NOTE: Do not apply engine oil to the crank case side Standard : 0.019 mm–0.043 mm bolts. (0.0007 in–0.0017 in) Main bearing cap bolts. Limit : 0.08 mm (0.0031 in) Torque: 39 N·m (29lb ft) Oil gallery fixing bolts. Torque: 1st step: 29 N·m (21 lb ft) 2nd step 55°∼...
Page 714 6A–72 ENGINE MECHANICAL 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 715 ENGINE MECHANICAL 6A–73 Crank Crank Shaft Bear- Shaft Bear- 1 Size Main Bearing Crank Shaft Main 2 Size ing Size ing Size Oil Clearance Mark Bore Diameter Journal Diameter Mark Mark Mark (Reference) (Upper (Lower Side) Side) 63.918-63.925 0.030-0.049 Blue Blue (2.5165-2.5167) (0.0012-0.0019)
Page 716 6A–74 ENGINE MECHANICAL 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 mounting faces. Â...
Page 717 ENGINE MECHANICAL 6A–75 4. Piston and connecting rod assembly (8) Â 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 718 6A–76 ENGINE MECHANICAL Legend (1) Portion Between Bolt Holes (2) Bolt Hole Portion 11. Install cylinder head assembly, refer to “Cylinder head” in this manual. 012RS001 7. Install oil pump assembly (5), refer to “Oil pump” in this manual. 8. Install oil strainer and O-ring (4). 9.
Page 719: Piston And Connecting Rod
ENGINE MECHANICAL 6A–77 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 720 6A–78 ENGINE MECHANICAL 015RS031 015RS023 Â 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 721 ENGINE MECHANICAL 6A–79 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 722 6A–80 ENGINE MECHANICAL 015RS026 015RS028 Â 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 723 ENGINE MECHANICAL 6A–81 Connecting Rods (11) 1. Check the connecting rod alignment If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm (3.937 in) Limit: 0.15 (0.0059) Twist per 100 mm (3.937 in) Limit: 0.20 (0.0078) 015RS031 3.
Page 724 6A–82 ENGINE MECHANICAL 4. Reinstall the rod caps (12) to their original 7. Clean the plastigage from the bearings and the positions. crankshaft pins. Tighten the rod cap nuts. Con–rod Bearing Selection Torque: 54 N·m (40 lb ft) Select and install the new connecting rod bearings, NOTE: Do not allow the crankshaft to rotate.
Page 725 ENGINE MECHANICAL 6A–83 Â Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side. 015RS027 Â Install piston rings in the following sequence. 1. Oil ring 1. Expander ring 015RS036 Â...
Page 726 6A–84 ENGINE MECHANICAL Â Tighten the connecting rod cap nuts Torque : 54 N·m (40 lb ft) NOTE: Do not apply engine oil to the bearing back faces. 6. Oil gallery, refer to “Crankshaft and main bearing” in this manual. 7.
Page 727: Cylinder Block
ENGINE MECHANICAL 6A–85 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 728 6A–86 ENGINE MECHANICAL 11. Remove rear oil seal retainer assembly. CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the 12. Remove main bearing cap. cylinder block. Be very careful not to scratch the 13.
Page 729 ENGINE MECHANICAL 6A–87 Â Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft. 012RS006 Reassembly 015RS013 3. Install rear oil seal retainer. 1. Install cylinder block. Â Remove oil on cylinder block and retainer fitting 2.
Page 730 6A–88 ENGINE MECHANICAL Â Check to see that the piston ring end gaps are correctly positioned. 015RW001 4. Install flywheel 1. Thoroughly clean and remove the oil from the 015RS019 threads of crankshaft. Legend 2. Remove the oil from the crankshaft and flywheel (1) No.1 Compression Ring mounting faces.
Page 731 ENGINE MECHANICAL 6A–89 012RS007 013RW010 7. Install cylinder block side bolts (1) and tighten Legend crankcase bolts in sequence shown in the illustration. (1) Portion Between Both Holes Torque : 39 N·m (29 lb ft) (2) Bolt Hole Portions 12. Install cylinder head gasket. 13.
Page 732 6A–90 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 733 ENGINE MECHANICAL 6A–91 Torque Specifications Ignition coil, Spark plug, Crankshaft angle sensor and Under cover E06RW001...
Page 734 6A–92 ENGINE MECHANICAL Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, EGR valve and EGR pipe E06RW012...
Page 735 ENGINE MECHANICAL 6A–93 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 736 6A–94 ENGINE MECHANICAL Connecting rod and Water pump E06RW011...
Page 737 ENGINE MECHANICAL 6A–95 Engine mount E06RW003...
Page 738: Special Tool
6A–96 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 739 ENGINE MECHANICAL 6A–97 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 740: Engine Cooling
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 741 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 742 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. Â Calculating mixing ratio 031RW002 Radiator The radiator is a tube type with corrugated fins.
Page 743 6B–4 ENGINE COOLING NOTE: Antifreeze solution + Water = Total cooling system capacity. Â Total Cooling System Capacity Â M/T 8.8Lit (2.32Us gal) Â A/T 8.4Lit (2.22Us gal) B06RW003 B06RW002 Â 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.
Page 744 6B–5 ENGINE COOLING Diagnosis Engine Cooling Trouble 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 Low engine oil level or use of Replenish or change oil...
Page 745 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 746: 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 747 6B–8 ENGINE COOLING 3. Idle pulley 4. Timing belt Â Install idle pulley and tighten bolt to the specified Â 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 748 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 749 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 750 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 751 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 drive belt tensioner is equipped.
Page 752 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 9.445mÂ (0.878ftÂ ) 11.21mÂ...
Page 753 6B–14 ENGINE COOLING Special Tool TOOL NO. ILLUSTRATION TOOL NAME J–24460–01 Tester; radiator cap J–33984–A Adapter; radiator cap...
Page 754: Table Of Contents
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 755 6C–2 ENGINE FUEL General Description 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 (12) Duty Solenoid Valve (5) Fuel Filter (13) Throttle Valve (6) Fuel Rail Right (14) Canister...
Page 756: Fuel Metering
ENGINE FUEL 6C–3 f 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 757: 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 3. Check the drain of receive rubber and if it is clogged with dust, clean it up with air.
Page 758: In–Tank Fuel Filter
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 759: 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 760: 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 761: Fuel Tube / Quick – Connect Fittings
6C–8 ENGINE FUEL f 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 762 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 763: Reuse Of Quick–Connector
6C–10 ENGINE FUEL Reuse of Quick–Connector (Delivery Pipe) f Replace the pipe and connector if scratch, dent or crack is found. f 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 764 ENGINE FUEL 6C–11 Fuel Gauge Unit Fuel Gauge Unit and Associated Parts 140RS004 Legend (1) Wiring Connector (2) Fuel Gauge Unit Removal CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section “Driveability and Emission”.
Page 765: 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 766: Engine Electrical
SECTION ENGINE ELECTRICAL 6D1–1 TROOPER ENGINE ENGINE ELECTRICAL CONTENTS Battery ....... . . 6D1–1 Jump Starting .
Page 767: Battery Charging
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 768: 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 769 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 770: Ignition 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 771 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 32 pin connector. wires without using a distributor.
Page 772: Ignition Coil
IGNITION SYSTEM 6D2–3 Ignition Coil Removal 1. Disconnect battery ground cable. 2. Ignition coil connector and ignition coil. f Disconnect three connector from ignition coil. f Remove harness bracket bolt on cylinder head cover. f Remove fixing bolts on ignition coil. 060RW006 Installation 1.
Page 773: Spark Plug
6D2–4 IGNITION SYSTEM Spark Plug Removal 1. Remove spark plugs. Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. f Check electrode and insulator for presence of cracks, and replace if any. f Check electrode for wear, and replace if necessary.
Page 774 IGNITION SYSTEM 6D2–5 Crankshaft Angle Sensor Removal 1. Disconnect battery ground cable 2. Wiring connector from crankshaft angle sensor. 3. Remove crankshaft angle sensor from cylinder block. 012RS008 Installation 1. Install crankshaft angle sensor into the cylinder block. Before installation,apply small amount of engine oil to the O–ring.
Page 775 6D2–6 IGNITION SYSTEM Main Data and Specifications General Specifications Ignition System Ignition Form Electronic Ignition System (El system) with Crankshaft angle 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 E06RW001...
Page 776 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 777: 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 778 STARTING AND CHARGING SYSTEM 6D3–3 C06RW005...
Page 779 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 780 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 781 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 782 STARTING AND CHARGING SYSTEM 6D3–7 Disassembly 9. Remove screws and through bolts, then the rear cover(9) then remove thrust washer(10). 1. Loosen the nut(1) on terminal “M” of magnetic switch 10. Remove brush holder(6). and disconnect the connector cable. 2. Remove bolt (2 pcs) (2). 065RW005 11.
Page 783 STARTING AND CHARGING SYSTEM 6D3–8 NOTE: In disassembling the yoke assembly, hold the 17. Remove ball bearing(19). armature and pull off slowly the yoke assembly. Because 18. Remove bearing cover(20). of strong magnetic force, avoid placing a metallic part 19. Remove a ball bearing and bearing cover from the near armature.
Page 784 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 785 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 786 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 787 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 788 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 789 6D3–14 STARTING AND CHARGING SYSTEM If the measured value is out of standard, insert dust cover, Characteristic Test or disassemble and adjust. 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 790 STARTING AND CHARGING SYSTEM 6D3–15 Main Data and Specifications General Specifications Model HITACHI GD002350 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 791 6D3–16 STARTING AND CHARGING SYSTEM Torque Specifications E06RW023...
Page 792 STARTING AND CHARGING SYSTEM 6D3–17 E06RW024...
Page 793: 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 794 STARTING AND CHARGING SYSTEM 6D3–19 Generator Removal Inspection 1. Disconnect battery ground cable. 1. Disconnect the wiring connector from generator. 2. Move drive belt tensioner to loose side using wrench 2. With the engine stopped, turn starter switch to “ON” then remove drive belt (1).
Page 795 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 796 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 797 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 798 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 799 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 800 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 801 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 802: Table Of Contents
SECTION TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–1 TROOPER ENGINE TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS CONTENTS Specifications ......6E–6 Maintenance Schedule .
Page 803 6E–2 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Evaporative Emission (EVAP) Purge Evaporative (EVAP) Emissions Canister System Vacuum Switch ....6E–54 Purge Valve Check ..... 6E–110 Misfire Monitor Diagnostic Operation .
Page 804: Table Of Contents
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–3 DTC P0155 – HO2S Heater Circuit DTC P0506 – Idle Air Control System Bank 2 Sensor 1 ..... . . 6E–217 Low RPM .
Page 805: Table Of Contents
6E–4 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Cuts Out, Misses Symptom ....6E–453 Wire Harness Repair: Twisted Shielded Hesitation, Sag, Stumble Symptom ..6E–456 Cable .
Page 806: Table Of Contents
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–5 Fuel Injector ......6E–517 Fuel Metering System Components .
Page 807: 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 — EGR Nut — Engine Coolant Temperature Sensor — Fuel Drain Plug —...
Page 808: Diagrams And Schematics
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–7 Diagrams and Schematics PCM Wiring Diagram (1 of 8) D06RW036...
Page 809 6E–8 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram (2 of 8) D06RW005...
Page 810 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–9 PCM Wiring Diagram (3 of 8) D06RW037...
Page 811 6E–10 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram (4 of 8) D06RW038...
Page 812 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–11 PCM Wiring Diagram (5 of 8, Automatic Transmission Only) D06RW039...
Page 813 6E–12 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram (6 of 8, Manual Transmission Only) D06RW003...
Page 814 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–13 PCM Wiring Diagram (7 of 8) D06RW040...
Page 815 6E–14 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram (8 of 8) D06RW006...
Page 816: Pcm Pinouts
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–15 PCM Pinouts PCM Pinout Table, 32-Way Red Connector – Row “A” TS23344 PIN Function Wire Color IGN ON ENG RUN Refer To 5 Volt Reference “A” 5.0 V 5.0 V Appropriate Sensor Knock Sensor 0.0 V DC 0.0 V DC...
Page 817 6E–16 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PIN Function Wire Color IGN ON ENG RUN Refer To EVAP Canister Purge RED/BLU 5.7 V General Description and Solenoid Operation, EVAP Emission Control System Band Apply (AT) BRN/YEL Automatic Transmission (4L30E) Air Pump (MT)
Page 818 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–17 PCM Pinout Table, 32-Way Red Connector – Row “B” TS23344 PIN Function Wire Color IGN ON ENG RUN Refer To 5 Volt Reference “B” RED/YEL 5.0 V 5.0 V Appropriate Sensor lgnition coil RED/WHT 0.0 V 0.1 V...
Page 819 6E–18 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 32-Way White Connector – Row “C” TS23345 PIN Function Wire Color IGN ON ENG RUN Refer To Injector Cylinder #4 GRN/RED General Description and Operation, Fuel Injector Shift “B” Solenoid BRN/BLK 0.0 V 0.0 V...
Page 820 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–19 PCM Pinout Table, 32-Way White Connector – Row “D” TS23345 PIN Function Wire Color IGN ON ENG RUN Refer To Injector Cylinder #2 GRN/ORN General Description and Operation, Fuel Injector Torque Converter Clutch BRN/BLU 0.0 V 0.0 V...
Page 821 6E–20 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PIN Function Wire Color IGN ON ENG RUN Refer To Bank 1 HO2S 3 High 0.4 V 0.1-0.9 V General Description and (Manual Transmission Operation, Catalyst Monitor Only) HO2S 3 Bank 1 HO2S 1 Low 0.0 V 0.1 V General Description and...
Page 822 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–21 PCM Pinout Table, 32-Way Blue Connector – Row “E” TS23346 PIN Function Wire Color IGN ON ENG RUN Refer To Transmission Output Shaft 0.0 V 0.1 V Automatic Transmission Sensor (TOSS) High (4L30E) Transmission Output Shaft 0.0 V...
Page 823 6E–22 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Pinout Table, 32-Way Blue Connector – Row “F” TS23346 PIN Function Wire Color IGN ON ENG RUN Refer To Not Used — — — — Transmission Range BLU/BLK 0.0 V 0.0 V Automatic Transmission Signal “C”...
Page 824: Component Locators
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–23 Component Locators Engine Component Locator 060RX066...
Page 825 6E–24 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 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 rear of 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 826: Undercarriage Component Locator
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–25 Undercarriage Component Locator F00RW032 Undercarriage Component Locator Table (Automatic Transmission) 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 Vent Solenoid On the top of the bracket that is located behind...
Page 827 6E–26 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Undercarriage Component Locator Table (Manual Transmission) 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 Vent Solenoid On the top of the bracket that is located behind...
Page 828 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–27 Sensors and Miscellaneous Component Locators T321064 T321068 T321065 014RW125 T321067 T321070...
Page 829 6E–28 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 141RW008 025RW005 055RW003 T321078 041RW004 060RW007...
Page 830 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–29 028RW001...
Page 831 6E–30 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 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 Tool, such as the Tech 2, have data-capturing capabilities that can assist in detecting intermittents.
Page 832: General Service Information
MIL (“Check Engine” This label is located in the engine compartment of every lamp). vehicle. If the label has been removed it should be replaced. It can be ordered from Isuzu Dealership.
Page 833: Maintenance Schedule
6E–32 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Maintenance Schedule On-Board Diagnostic (OBD II) Refer to the Maintenance Schedule . On-Board Diagnostic Tests Visual / Physical Engine Compartment A diagnostic test is a series of steps, the result of which is Inspection a pass or fail reported to the diagnostic executive.
Page 834: Common Obd Ii Terms
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–33 Output Components: System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance Output components are diagnosed for proper response to control module commands. Components where (I/M 240) Regulations functional monitoring is not feasible will be monitored for I/M Ready Status means a signal or flag for each circuit continuity and out-of-range values if applicable.
Page 835: The Diagnostic Executive
6E–34 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Trip There is a continuous self-diagnosis on certain control functions. This diagnostic capability is complemented by Technically, a trip is a key on-run-key off cycle in which all the diagnostic procedures contained in this manual. The the enable criteria for a given diagnostic are met, allowing language of communicating the source of the malfunction the diagnostic to run.
Page 836: Dtc Types
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–35 f When the MIL remains “ON” while the engine is f Stores Fail Record when test fails running, or when a malfunction is suspected due to a f Updates the Fail Record each time the diagnostic driveability or emissions problem, a Powertrain test fails On-Board Diagnostic (OBD ll) System Check must be...
Page 837: Verifying Vehicle Repair
6E–36 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f Engine Load encoding involves the use of a two additional numbering f Engine Coolant Temperature systems: Binary and Hexadecimal. The binary number system has a base of two numbers. f Vehicle Speed Each digit is either a 0 or a 1.
Page 838 NOTE: To prevent system damage, the ignition key must Tech 2 be “OFF” when disconnecting or reconnecting battery From 98 MY, Isuzu dealer service departments are power. recommended to use the Tech 2, Scan Tool. Please refer f The power source to the control module. Examples: to the Tech 2 user guide.
Page 839: Tech 2 Features
Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4).
Page 840 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–39 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. 060RX057 060RX060...
Page 841: Dtc Modes
6E–40 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Menu f 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 060RW224 they will appear on the Tech 2.
Page 842: Miscellaneous Test
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–41 History 3. Select F3: Miscellaneous Test in the Application Menu. This selection will display only DTCs that are stored in the PCM’s history memory. It will display all type A and B DTCs that have requested the MIL and have failed within the last 40 warm-up cycles.
Page 843: Relays Test
6E–42 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 5. Select F0:Malfunction Indicator Lamp. 3. Select F3: Miscellaneous Test in the Application Menu. 060RX019 6. Push”On” soft key. 060RW228 4. Select F1:Relay Test in the Miscellaneous Test. 7. Make sure Lamp illuminates. 8.
Page 844: Evap Test
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–43 5. Select F0:Fuel Pump Relay. 11. Turn on Air Condtioning. 060RX021 060RX023 6. Push “On” soft key. 12. Push “On” and “Off” soft keys. 13. Contol A/C Clutch Relay and check data list. 14.
Page 845 6E–44 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 4. Select F2:EVAP Test in the Miscellaneous Test. 6. Push “Decrease” or “Increase” soft key. 060RX036 060RX026 5. Select F0: Purge Solenoid. 7. Control EVAP Purge Solenoid and check a data list. 8.
Page 846: Idle Air Control System Test
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–45 11. Push “On” or “Off” soft key. 4. Select F3: IAC System Test in the Miscellaneous Test. 060RX027 12. Control EVAP Vent Solenoid and check data list. 060RX007 5. Select F1: IAC Control Test. 13.
Page 847: Fuel System Test
6E–46 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 7. Control IAC system and check data list. 16. If data list changes, the IAC has been Reset. 060RX015 060RW231–1 8. If the data list changes, the IAC Control is normal. Fuel System Test 9.
Page 848 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–47 4. Select F4: Fuel System in the Miscellaneous Menu. 6. Push “Decrease” or “Increase” soft key. 060RX032 060RX030 5. Select F1: Fuel Gauge Level 7. Control Fuel Level and check data list. 8.
Page 849: Egr Control Test
6E–48 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 10. Push “Reset” of soft key. 4. Select F5: EGR Control Test in the Miscellaneous Test. 060RX029 060RX008 EGR Control Test 5. Control EGR Valve and check data list. This test is conducted check EGR valve for proper operation.
Page 850: Injector Balance Test
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–49 3. Select F3: Miscellaneous Test in the Application 5. Push “On” or “Off” of soft key. Menu. 060RX028 6. Control VIM Solenoid check data list. 060RW228 4. Select F6: Variable Intake Manifold Solenoid Test. 7.
Page 851: Plottong Snapshot Graph
6E–50 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 4. Select F7: Injector Balance Test in the Miscellaneous 6. Make sure of engine speed change. Test. 7. If engine speed changes, the injector electric circuit is normal. If engine speed does not change, the injector electric circuit or the injector itself is not normal.
Page 852 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–51 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) 060RX041...
Page 853 6E–52 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Flow Chart for Snapshot Replay (Plotting Graph) 060RX040...
Page 854: Ho2S Heater
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–53 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 855 6E–54 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f 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 856 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–55 firing events which were misfires. The misfire current Fuel Trim System Monitor Diagnostic counter will display real time data without a misfire DTC Operation stored. The misfire history counters (Misfire Hist #1-6) indicate the total number of cylinder firing events which Fuel Trim System Monitor Diagnostic were misfires.
Page 857 6E–56 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS On-Board Diagnostic (OBD II) System Check TS321119 Circuit Description Test Description Number(s) below refer to the step number(s) on the The on-board diagnostic system check is the starting Diagnostic Chart: point for any driveability complaint diagnosis. Before using this procedure, perform a careful visual/physical 1.
Page 858 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–57 10.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.
Page 859 6E–58 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS On-Board Diagnostic (OBD II) System Check (Cont'd) Step Action Value(s) 1. Attempt to reprogram the PCM. Refer to Powertrain Control Module (PCM) in On-Vehicle Service. 2. Attempt to display PCM data with the Tech 2. Does the Tech 2 display PCM engine data? —...
Page 860 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–59 A/C Clutch Control Circuit Diagnosis D06RW085 f The throttle is greater than 90%. Circuit Description f The ignition voltage is below 10.5 volts. When air conditioning and blower fan are selected, and if f The engine speed is greater than 4500 RPM for 5 the system has a sufficient refrigerant charge, a 12-volt signal is supplied to the A/C request input of the...
Page 861 6E–60 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f Damaged harness–Inspect the wiring harness for 3. This a test determine is the problem is with the damage. If the harness appears to OK, observe the refrigerant system. If the switch is open, A/C A/C clutch while moving connectors and wiring pressure gauges will be used to determine if the harnesses related to the A/C.
Page 862 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–61 A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) 1. Engine idling. 2. A/C “ON”. 3. Blower “ON”. 4. Observe the “A/C Request” display on the Tech 2. (Refer to the Miscellaneous test) Does the tool “A/C Request”...
Page 863 6E–62 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) Replace the A/C switch. Is the action complete? — Verify repair — Use an ohmmeter to check continuity between the electronic A/C thermostat and the blower switch. Was there an open circuit? —...
Page 864 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–63 A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) Replace the PCM. IMPORTANT: The replacement must Refer to On-Vehicle Service in programmed. Powertrain Control Module Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not.
Page 865 6E–64 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) Repair the open circuit between the compressor Clutch and the A/C compressor relay. Is the action complete? — Verify repair — Service the compressor clutch or replace the compressor due to a faulty internal overheat switch.
Page 866 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–65 Electronic Ignition System Diagnosis Refer to Rough, Unstable, or Incorrect Idle, Stalling in Symptoms for other possible causes of idle problems. If the engine cranks but will not run or immediately stalls, the Engine Cranks But Will Not Start chart must be used Fuel System Pressure Test to determine if the failure is the ignition system or the fuel...
Page 867 6E–66 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f The voltage displayed by the DVM should be within Highest Acceptable Acceptable Subtracted the specified range. Voltage Reading Value f The voltage displayed by the DVM may increase Above/Below 35°C/10°C throughout the test as the fuel injector windings (95°F/50°F) warm and the resistance of the fuel injector windings 9.5 Volts...
Page 868 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–67 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 869 6E–68 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. Set injector switch box injector #1. 2. Press the “Push to Start Test” button on the fuel injector tester.
Page 870 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–69 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 871 6E–70 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Knock Sensor Diagnosis Multiple PCM Information Sensor DTCS Set The Tech 2 has two data displays available for diagnosing the knock sensor (KS) system. The two displays are described as follows: Circuit Description f “Knock Retard”...
Page 872 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–71 f P0122/P1122 f IAT f ECT An the in the 5-volt reference circuit B, between the PCM and the splice, will cause one or more of the following f TP DTCs to be set: f MAP f P0107/P1107 f EGR...
Page 873 6E–72 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Multiple PCM Information Sensor DTCs Set (Cont'd) Step Action Value(s) Measure the voltage between the IAT sensor signal circuit at the PCM harness connector and ground. Does the voltage measure near the specified value? Go to Step 10 Go to Step 17 Measure the voltage between the ECT sensor signal...
Page 874 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–73 Exhaust Gas Recirculation (EGR) ECT — (Engine Coolant Temperature) Tech 2 Range –40°C to 151°C (–40°F to 304°F) — Diagnosis The engine coolant temperature (ECT) is mounted in the An EGR flow check diagnosis of the linear EGR system is coolant stream sends...
Page 875 6E–74 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS FUEL TRIM CELL — Tech 2 Range 0-21 — HO2S BANK 2, SEN. 2 (Auto Trans)—Tech 2 Range The fuel trim cell is dependent upon engine speed and 0-1000 mV— MAF sensor readings. A plot of RPM vs. MAF is divided Monitors the exhaust oxygen sensor output voltage.
Page 876 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–75 INJ. PULSE BANK 1/INJ. PULSE BANK 2 — Tech 2 MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 — Tech 2 Range 0-1000 msec. — Range 0-255 Counts — Indicates the amount of time the PCM is commanding The misfire current counters increase at a rate according each injector “ON”...
Page 877 6E–76 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS CATALYST PROTECTION MODE — Tech 2 Displays YES or NO — “YES” displayed indicates that the PCM has detected conditions appropriate to operate in TWC protection mode. The PCM will decrease the air/fuel ratio to a value that depends on mass air flow (higher mass air flow = lower air/fuel ratio).
Page 878 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–77 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 Operation, A/C Clutch Circuit Operation A/C Request...
Page 879 6E–78 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) Engine Load Engine Percent 2.0% - 5.5% 8.0% - 16.0% General Description and Operation, Mass Air Flow (MAF) Sensor Time From Start Engine...
Page 880 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–79 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 881 6E–80 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) MAF (Mass Air Engine Grams per 2.85-6.65 9.5-16.5 General Description and Flow) second Operation, MAF; DTCs: P101, P0102, P0103 MAP kPa Engine...
Page 882 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–81 Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) Spark Engine Degrees 15-22 34-44 General Description and (Advance) Before Top Operation, Electronic Dead Ignition System Center Start-Up ECT...
Page 883 6E–82 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS No Malfunction Indicator Lamp (MIL) D06RW029 f If the engine cranks but will not run, check for an open Circuit Description PCM ignition or battery feed, or a poor PCM to engine The “Check Engine”...
Page 884 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–83 17.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.
Page 885 6E–84 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS No Malfunction Indicator Lamp (MIL) (Cont'd) Step Action Value(s) Repair the open in the ignition feed circuit. Is the action complete? — Verify repair — Locate and repair the open PCM battery feed circuit. Is the action complete? —...
Page 886 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–85 Malfunction Indicator Lamp (MIL) “ON” Steady D06RW023 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 887 6E–86 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 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 888 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–87 Engine Cranks But Will Not Run D06RW024...
Page 889 6E–88 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Circuit Description Test Description Number(s) below refer to the step number(s) on the The electronic Ignition system uses a coil-at-plug method Diagnostic Chart. of spark distribution. In this type of ignition system, the powertrain control module (PCM) triggers the correct 5.
Page 890 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–89 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 891 6E–90 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 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 892 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–91 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 893 6E–92 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 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 894 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–93 Fuel System Electrical Test D06RW004 Circuit Description Diagnostic Aids When the ignition switch is first turned “ON,” the An intermittent may be caused by a poor connection, powertrain control module (PCM) energizes the fuel rubbed-through wire insulation, or a wire broken inside pump relay which applies power to the in-tank fuel pump.
Page 895 6E–94 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS CAUTION: To reduce the risk of fire and personal 2. Remove the fuel pump relay from the underhood injury: relay center. f It is necessary to relieve fuel system pressure 3. Start the engine and allow it to stall. before connecting a fuel pressure gauge.
Page 896 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–95 Fuel System Electrical Test (Cont'd) Step Action Value(s) Check for short or open between the PCM and the fuel pump relay. Was a problem found? — Verify repair Go to Step 10 1.
Page 897 6E–96 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 898 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–97 f 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 899 6E–98 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 900 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–99 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 901 6E–100 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 902 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–101 Idle Air Control (IAC) System Check f Throttle body – Remove the IAC valve and inspect the Circuit Description bore for foreign material. The powertrain control module (PCM) controls engine f IAC valve electrical connections – IAC valve idle speed with the idle air control (IAC) valve.
Page 903 6E–102 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Idle Air Control (IAC) System Check Step Action Value(s) 1. Ignition “OFF.” 2. Connect the IAC motor analyzer J37027-A to the IAC valve. 3. Set the parking brake. 4. Block the wheels. 5.
Page 904 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–103 Idle Air Control (IAC) System Check (Cont'd) Step Action Value(s) 1. Check the resistance between the IAC terminal B and terminal C. 2. Check the resistance between the IAC terminal A and terminal D. Go to Step 11 Go to Step 12 Is the resistance infinite?
Page 905 6E–104 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy) D06RW035–1 Circuit Description Test Description The numbers below refer to the step numbers on the The knock sensor (KS) sends an AC voltage signal to the Diagnostic Chart.
Page 906 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–105 Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy) (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.
Page 907 6E–106 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Exhaust Gas Recirculation (EGR) System Check D06RW022 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 908 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–107 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 909 6E–108 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Manifold Absolute Pressure (MAP) Output Check D06RW025 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 910 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–109 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 911 6E–110 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Evaporative (EVAP) Emissions Canister Purge Valve Check D06RW018 Circuit Description Diagnostic Aids f Make a visual check of vacuum hoses. Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. f Check the throttle body for possible cracked.
Page 912 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–111 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 913 6E–112 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 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 914 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–113 Upshift Lamp System Check (Manual Transmission Only) D06RW040...
Page 915 6E–114 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 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 916 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–115 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 917 6E–116 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PCM Diagnostic Trouble Codes The following table lists the diagnostic trouble codes be faulty; notify the Tech 2 manufacturer of any DTCs supported by this vehicle application. If any DTCs not displayed that are not included in the following table. listed here are displayed by a Tech 2, the Tech 2 data may PCM Diagnostic Trouble Codes Description...
Page 918 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–117 Description Type Illuminate MIL P0172 Fuel Trim System Rich Bank 1 P0174 Fuel Trim System Lean Bank 2 P0175 Fuel Trim System Rich Bank 2 P0201 Injector 1 Control Circuit P0202 Injector 2 Control Circuit P0203 Injector 3 Control Circuit P0204...
Page 919 6E–118 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Description Type Illuminate MIL P0463 Fuel Level Sensor Circuit-High Voltage P0502 VSS Circuit Low Input P0506 Idle Air Control System Low RPM P0507 Idle Air Control System High RPM P0562 System Voltage Low P0563 System Voltage High P0601...
Page 920 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–119 Description Type Illuminate MIL P1154 HO2S Transition Time Ratio Bank 2 Sensor 1 P1171 Fuel System Lean During Acceleration P1380 ABS Rough Road ABS System Fault P1381 ABS Rough Class 2 Serial Link Error P1404 EGR Close Stuck P1441...
Page 921 6E–120 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0101 MAF System Performance T321122 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given (MIL) after the second consecutive trip in which the fault is detected.
Page 922 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–121 f The duct work at the MAF sensor for leaks. 2. The MAF system performance or “rationality” f An engine vacuum leak. diagnostic uses the MAP sensor signal along with other input to calculate an expected airflow rate that f The PCV system for vacuum leaks.
Page 923 6E–122 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0101 – MAF System Performance (Cont'd) Step Action Value(s) 1. Connect the MAF Sensor wiring harness connector to the MAF Sensor. 2. Connect the Tech 2 to the vehicle. 3. Place the Transmission in Park/Neutral, and fully apply the Parking Brake.
Page 924 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–123 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency T321122 f The PCM will store conditions which were present Circuit Description when the DTC was set as Freeze Frame and in the The mass air flow (MAF) sensor measures the amount of Failure Records data.
Page 925 6E–124 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS about 3-6 g/second at idle to 100 g/second or greater 2. This step verifies that the problem is present at idle. at the time of the 1-2 shift. If not, check for a restriction. 4.
Page 926 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–125 DTC P0102 – MAF Sensor Circuit Low Frequency (Cont'd) Step Action Value(s) 1. Ignition “OFF.” 2. Disconnect the PCM white connector. 3. Ignition “ON.” 4. Check the MAF sensor signal circuit for a short to 5 volts.
Page 927 6E–126 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency T321122 f The PCM calculates an airflow value based on idle air Circuit Description control valve position, throttle position, RPM and The mass air flow (MAF) sensor measures the amount of barometric pressure.
Page 928 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–127 4. A frequency reading with the MAF sensor connector disconnected indicates an electromagnetic interfernce (EMI) related fault. 9. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM).
Page 929 6E–128 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0103 – MAF Sensor Circuit High Frequency Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Ignition “ON,” engine “OFF.” 2.
Page 930 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–129 Diagnostic Trouble Code (DTC) P0106 MAP System Performance D06RW025 f The MAP value must vary for a total of 10 seconds over Circuit Description a 20-second period of time that the samples were The manifold absolute pressure (MAP) sensor responds monitored.
Page 931 6E–130 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f Damaged harness – Inspect the wiring harness for determining vehicle mileage since the DTC was last set. damage. If the harness appears to be OK, observe the If it is determined that the DTC occurs intermittently, MAP display on the Tech 2 while moving connectors performing the DTC P1106 or P1107 Diagnostic Chart and wiring harnesses related to the sensor.
Page 932 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–131 DTC P0106 – MAP System Performance (Cont'd) Step Action Value(s) 1. Check the 5 volt reference “A” circuit for high resistance, an open between the PCM and the MAP sensor, or a poor connection at the PCM. 2.
Page 933 6E–132 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage D06RW025 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum).
Page 934 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–133 locks, improperly formed or damaged terminals, and If DTC P0107 cannot be duplicated, the information poor terminal-to-wire connection. included in the Failure Records data can be useful in f Damaged harness – Inspect the wiring harness for determining vehicle mileage since the DTC was last set.
Page 935 6E–134 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0107 – MAP Sensor Circuit Low Voltage (Cont'd) Step Action Value(s) 1. Ignition “OFF.” 2. Disconnect the PCM, and check the MAP signal circuit for an open, short to ground, or short to the sensor ground circuit.
Page 936 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–135 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage D06RW025 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum).
Page 937 6E–136 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS locks, improperly formed or damaged terminals, and If DTC P0108 cannot be duplicated, the information poor terminal-to-wire connection. included in the Failure Records data can be useful in f Damaged harness – Inspect the wiring harness for determining vehicle mileage since the DTC was last set.
Page 938 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–137 DTC P0108 – MAP Sensor Circuit High Voltage (Cont'd) Step Action Value(s) 1. Check the continuity of the MAP sensor ground circuit. 2. If the MAP sensor ground circuit measures over 5 ohms, repair open or poor connection.
Page 939 6E–138 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage D06RW026 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL “OFF” on the third The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.
Page 940 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–139 3. If DTC P0112 can be repeated only by duplicating the Failure Records condition, refer to the Temperature vs. Resistance Value table. The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a “shifted”...
Page 941 6E–140 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0112–IAT Sensor Circuit Low Voltage Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Ignition “ON,” engine “OFF.” 2.
Page 942 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–141 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage D06RW026 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL “OFF” on the third The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.
Page 943 6E–142 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Test Description Intake Air Temperature Sensor Number(s) below refer to the step number(s) on the °C °F OHMS Diagnostic Chart: Temperature vs. Resistance Values 2. Verifies that the fault is present. (approximate) 3.
Page 944 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–143 DTC P0113 –IAT Sensor Circuit High Voltage (Cont'd) Step Action Value(s) Check for poor connections at the IAT sensor and replace terminals if necessary. Did any terminals require replacement? — Verify repair Go to Step 10 1.
Page 945 6E–144 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage D06RW027 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL “OFF” on the third The engine coolant temperature (ETC) sensor is a thermistor mounted on a coolant crossover pipe at the consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.
Page 946 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–145 Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P0117 can be repeated only by duplicating the Failure Records conditions, refer to the “Temperature vs.
Page 947 6E–146 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0117 – ECT Sensor Low Voltage Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Ignition “ON,” engine “OFF.” 2.
Page 948 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–147 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage D06RW027 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL “OFF” on the third The engine coolant temperature (ETC) sensor is a thermistor mounted in on a coolant crossover pipe at the consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.
Page 949 6E–148 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS performing the DTC P1115 Diagnostic Chart may isolate Engine Coolant Temperature Sensor the cause of the fault. °C °F OHMS Test Description Temperature vs. Resistance Values Number(s) below refer to the step number(s) on the (approximate) Diagnostic Chart.
Page 950 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–149 DTC P0118 – ECT Sensor Circuit High Voltage (Cont'd) Step Action Value(s) 1. Ignition “OFF.” 2. Disconnect the PCM, and check the ECT sensor ground circuit for an open. 3. If the ECT sensor ground circuit is open, repair it as necessary.
Page 951 6E–150 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0121 TP System Performance D06RW028 f The PCM will store conditions which were present Circuit Description when the DTC was set as Freeze Frame and in the The throttle position (TP) sensor circuit provides a voltage Failure Records data.
Page 952 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–151 f Poor connection at PCM – Inspect harness connectors If DTC P0121 cannot be duplicated, the information for backed-out terminals, improper mating, broken included in the Failure Records data can be useful in locks improperly formed or damaged terminals, and determining vehicle mileage since the DTC was last set.
Page 953 6E–152 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0121 –TP System Performance (Cont'd) Step Action Value(s) Check the following items: 1. TP signal circuit for a short to voltage. 2. TP sensor ground circuit for high resistance between the PCM and the TP sensor. 3.
Page 954 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–153 Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage D06RW028 f DTC P0122 can be cleared by using the Tech 2 “Clear Circuit Description Info” function or by disconnecting the PCM battery The throttle position (TP) sensor circuit provides a voltage feed.
Page 955 6E–154 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0122 –TP Sensor Circuit Low Voltage Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Ignition “ON,” engine “OFF.” 2.
Page 956 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–155 DTC P0122 –TP Sensor Circuit Low Voltage (Cont'd) Step Action Value(s) Check the TP sensor signal circuit for a poor connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? —...
Page 957 6E–156 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage D06RW028 f DTC P0123 can be cleared by using the Tech 2 “Clear Circuit Description Info” function or by disconnecting the PCM battery The throttle position (TP) sensor circuit provides a voltage feed.
Page 958 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–157 f EGR valve performing the DTC P1121 Diagnostic Chart may isolate the cause of the fault. Disconnect the component while observing the TP sensor display on the Tech 2. If the reading Test Description changes drastically when this component is disconnected, replace the component that...
Page 959 6E–158 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0123 – TP Sensor Circuit High Voltage (Cont'd) Step Action Value(s) 1. Ignition “OFF,” disconnect the PCM. 2. Ignition “ON,” engine “OFF.” 3. Check for a short to B+ on the 5 volt reference “A” circuit.
Page 960 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–159 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control D06RW027 f For a warm engine (intake air temperature is greater Circuit Description than 10°C/50°F), engine coolant temperature To provide the best possible combination of driveability, sufficient allow “closed...
Page 961 6E–160 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Aids Engine Coolant Temperature DTC P0125 set indicates a faulty ECT sensor. °C °F OHMS Comparing the engine coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a Temperature vs.
Page 962 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–161 DTC P0125 –ECT Excessive Time to Closed Loop Fuel Control (Cont'd) Step Action Value(s) Compare engine coolant temperature displayed on the Tech 2 to the actual coolant temperature measured with a thermometer. (Observe normal precautions when opening the cooling system.) Is the Tech 2 engine coolant temperature indication close to the measured temperature?
Page 963 6E–162 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1 D06RW008 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen (MIL) the first time the fault is detected.
Page 964 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–163 f Vacuum leaks – Check for disconnected or damaged f If none of the above conditions are present, replace the vacuum hoses and for vacuum leaks at the intake affected HO2S. manifold, throttle body, EGR system, and PCV system. Test Description f Exhaust leaks –...
Page 965 6E–164 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0131 –HO2S Circuit Low Voltage Bank 1 Sensor 1 (Cont'd) Step Action Value(s) Repair the short between the high and low circuits. Is the action complete? — Verify repair — 1. Ignition “OFF.” 2.
Page 966 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–165 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1 D06RW008 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen (MIL) the first time the fault is detected.
Page 967 6E–166 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f MAF sensor –The system can go rich if MAF sensor An HO2S which is faulty and not allowing a full voltage signal indicates an engine airflow measurement that is swing between the rich and lean thresholds can also not correct.
Page 968 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–167 DTC P0132 – HO2S Circuit High Voltage Bank 1 Sensor 1 (Cont'd) Step Action Value(s) 1. Ignition “ON,” engine“OFF.” 2. At Bank 1 HO2S 1 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground.
Page 969 6E–168 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1 D06RW008 f All above conditions are met for 3 seconds. Circuit Description f 90 seconds after “closed loop” has been enabled, The powertrain control module (PCM) continuously Bank1 HO2S 1 average transition time between monitors the heated oxygen sensor (HO2S) activity for 90...
Page 970 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–169 locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. f Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor.
Page 971 6E–170 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0133 – HO2S Slow Response Bank 1 Sensor 1 Step Action Value(s) Go to OBD Was the “On-Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 NOTE: If any DTCs are set (expect P0153, P1133, P1134, P1153, and/or P1154), refer to those DTCs before proceeding with this diagnostic chart.
Page 972 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–171 DTC P0133 – HO2S Slow Response Bank 1 Sensor 1 (Cont'd) Step Action Value(s) Visually/physically inspect the following items: Ensure that the Bank 1 HO2S 1 is securely installed. Check for corrosion on terminals. Check terminal tension (at Bank 1 HO2S 1 and at the PCM).
Page 973 6E–172 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 D06RW010 f Oxygen sensor heater has been determined to be Circuit Description functioning properly. f The powertrain control module (PCM) supplies a bias f Bank 1 HO2S 1 signal voltage remains between voltage of about 450 mV between the heated oxygen 400 mV and 500 mV for a total of 77 seconds over a...
Page 974 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–173 damaged terminals, poor terminal-to-wire connection, and related connectors. If the fault is induced, the and damaged harness. HO2S signal voltage will change. This may help isolate the location of the malfunction. f Faulty HO2S heater or heater circuit – With the ignition “ON,”...
Page 975 6E–174 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0134 –HO2S Circuit Insufficient Activity Bank 1 Sensor 1 (Cont'd) Step Action Value(s) 1. Ignition “OFF.” 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 low circuit. 3.
Page 976 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–175 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1 D06RW010 f Engine coolant temperature (ECT) is less than 32°C Circuit Description (90°F) at start-up. Heated oxygen sensors are used to minimize the amount f IAT and ECT are within 6°C (11°F) of each other at of time required for “closed loop”...
Page 977 6E–176 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f DTC P0135 can be cleared by using the Tech 2 “Clear Test Description Info” function or by disconnecting the PCM battery Number(s) below refer to the step number(s) on the feed. Diagnostic Chart.
Page 978 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–177 DTC P0135 – HO2S Heater Circuit Bank 1 Sensor 1 (Cont'd) Step Action Value(s) 1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure the resistance between the Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1 heater ground at the Bank 1 HO2S 1 pigtail.
Page 979 6E–178 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2 D06RW015 f Bank 1 HO2S 2 signal voltage remains below 400 mV Circuit Description during power enrichment mode fuel control operation The powertrain control module (PCM) supplies bias for up to 5 seconds.
Page 980 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–179 compensate for some decrease. However, if fuel alcohol in the fuel can also cause this condition. Refer pressure is too low, a DTC P0137 may be set. Refer to Fuel System Diagnosis for procedure to check for to Fuel System Diagnosis .
Page 981 6E–180 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0137 –HO2S Circuit Low Voltage Bank 1 Sensor 2 (Cont'd) Step Action Value(s) Repair the short between the high and low circuits. Is the action complete? — Verify repair — 1. Ignition “OFF.” 2.
Page 982 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–181 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2 D06RW015 f Bank 1 HO2S 2 signal voltage remains above 500 mV Circuit Description during deceleration fuel cut–off mode operation for up The powertrain control module (PCM) supplies bias to 3 seconds.
Page 983 6E–182 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f Evaporative emissions (EVAP) canister purge – Check f Open HO2S Signal Circuit of Faulty HO2S – A poor for fuel saturation. If full of fuel, check the canister connection or open in the HO2S signal circuit can control and hoses.
Page 984 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–183 DTC P0138 – HO2S Circuit High Voltage Bank 1 Sensor 2 (Cont'd) Step Action Value(s) Repair short to voltage in the signal circuit. Is the action complete? — Verify repair — 1. Ignition “ON,” engine“OFF.” 2.
Page 985 6E–184 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2 D06RW011 Circuit Description maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine. To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a Conditions for Setting the DTC three-way catalytic converter is used.
Page 986 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–185 f Intermittent test–With the ignition “ON,” monitor the Diagnostic Aids HO2S signal voltage while moving the wiring harness Check for the following conditions: and related connectors. If the fault is induced, the f Poor connection or damaged harness–...
Page 987 6E–186 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0140 – HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 (Cont'd) Step Action Value(s) 1. Ignition “OFF.” 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 2 high circuit. 3.
Page 988 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–187 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2 D06RW011 f Engine coolant temperature (ECT) is less than 32°C Circuit Description (90°F) at start-up. Heated oxygen sensors are used to minimize the amount f IAT and ECT are within 6°C (11°F) of each other at of time required for closed loop fuel control operation and start-up.
Page 989 6E–188 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS f DTC P0141 can be cleared by using the Tech 2 “Clear 2. The HO2S should be allowed to cool before Info” function or by disconnecting the PCM battery performing this test. If the HO2S heater is feed.
Page 990 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–189 DTC P0141 – HO2S Heater Circuit Bank 1 Sensor 2 (Cont'd) Step Action Value(s) Connect the test light between the Bank 1 HO2S 2 ignition feed and the Bank 1 HO2S 2 heater ground. Does the test light illuminate? —...
Page 991 6E–190 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0143 HO2S Circuit Low Voltage Bank 1 Sensor 3 D06RW016 f “Closed loop” commanded air/fuel ratio is between Circuit Description 14.5 and 14.8. To control emissions of hydrocarbons (HC), carbon f Throttle angle is between 3% and 19%.
Page 992 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–191 f Fuel contamination – Water, even in small amounts, Diagnostic Aids can be delivered to the fuel injectors. The water can Check for the following conditions: cause a lean exhaust to be indicated. Excessive f Heated oxygen sensor wiring –...
Page 993 6E–192 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0143 –HO2S Circuit Low Voltage Bank 1 Sensor 3 (Cont'd) Step Action Value(s) 1. Turn the ignition “OFF,” HO2S 3 and PCM disconnected. 2. Check for continuity between the high and low signal circuits.
Page 994 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–193 Diagnostic Trouble Code (DTC) P0144 HO2S Circuit High Voltage Bank 1 Sensor 3 D06RW016 f “Closed loop” commanded air/fuel ratio is between Circuit Description 14.5 and 14.8. To control emissions of hydrocarbons (HC), carbon f Throttle angle is between 3% and 19%.
Page 995 6E–194 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Aids HO2S voltage to be indicated. This condition is indicated by a powdery white deposit on the portion of Check for the following conditions: the HO2S exposed to the exhaust stream. f Fuel pressure –...
Page 996 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–195 DTC P0144 – HO2S Circuit High Voltage Bank 1 Sensor 3 (Cont'd) Step Action Value(s) 1. Ignition “OFF.” 2. Disconnect Bank 1 HO2S 1. 3. Ignition “ON.” 4. At HO2S Bank 1 Sensor 3 connector (PCM side) use a DVM to measure voltage at the high and low signal terminals.
Page 997 6E–196 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Diagnostic Trouble Code (DTC) P0146 HO2S Circuit Insufficient Activity Bank 1 Sensor 3 D06RW012 Circuit Description Bank 1 HO2S 2 signal will be far more active than that produced by the Bank 1 HO2S 3 sensor. If the Bank 1 To control emissions of hydrocarbons (HC), carbon HO2S 3 signal voltage remains at or near the 450 mV bias monoxide (CO), and oxides of nitrogen (NOx), a...
Page 998 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–197 f Oxygen sensor heater is operating properly. damaged terminals, poor terminal-to-wire connection, and damaged harness. f Engine is operating in “closed loop.” f Faulty HO2S heater or heater circuit – With the ignition f Bank 1 HO2S 3 signal voltage remains between “ON,”...
Page 999 6E–198 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0146 –HO2S Circuit Insufficient Activity Bank 1 Sensor 3 (Cont'd) Step Action Value(s) Check for poor Bank 1 HO2S 3 high and low signal circuit terminal connections at the PCM and replace the terminal(s) if necessary.
Page 1000 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–199 Diagnostic Trouble Code (DTC) P0147 HO2S Heater Circuit Bank 1 Sensor 3 D06RW012 operating temperature is based on the total amount of air Circuit Description that has passed through the MAF sensor and into the Heated oxygen sensors are used to minimize the amount engine (more total airflow = shorter time to HO2S of time required for closed loop fuel control operation and...

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