check engine ISUZU TROOPER 1998 Service Repair Manual

7A1±72
TRANSMISSION CONTROL SYSTEM (4L30±E)
DTC P1860 TCC Solenoid Electrical
StepActionYe sNo
11. Install the scan tool.
2. With the engine ªonº, turn the ignition switch ªonº.
NOTE: Before clearing DTC(s), use the scan tool to record ªFailure
Recordsº for reference, as data will be lost when theªClear Infoº
function is used.
3. Record the DTC ªFailure Recordsº.
Go to Step 2Go to Step 3
2Using the J39200 DVOM, back probe between PCM connector
terminals J2±D2 and J2±C8.
Is the voltage 0 ?
Go to Step 4Go to Step 5
31. Apply brake pedal and select transmission range ªDº.
2. Do a test drive, and increase the vehicle speed to TCC ªonº at
4th.
Does the scan tool display DTC P1860 at TCC ªONº?
Go to Step 9
Go to Diagnostic
Aids
41. Turn the ignition ªoffº.
2. Disconnect the J2 (WHITE) PCM connector.
3. Using the J39200 DVOM, measure the resistance between
PCM connector terminals J2±D2 and J2±C8.
Is the resistance within 18 ± 20 ohms?
Go to Step 6Go to Step 7
5The wiring harness between PCM connector terminal J2±D2 and
transmission adapter case connector terminal M6±4(A) is shorted
to voltage.
Was a problem found and corrected?
Go to Step 18Go to Step 19
6Intermittent condition.
Check the wiring harness and terminals between PCM connector
J2 and transmission adapter case connector M±6.
Was a problem found and corrected?
Go to Step 18Go to Step 19
71. Disconnect the transmission 16±way connector H±53.
2. Using the J39200 DVOM, measure the resistance between
terminal H53±8 and ground.
Is the resistance within 18 ± 20 ohms?
Go to Step 15Go to Step 8
81. Disconnect the transmission adapter case connector M±6.
2. Using the J39200 DVOM, measure the resistance between
terminal M6±4(A) and ground.
Is the resistance within 18 ± 20 ohms?
Go to Step 16Go to Step 17
91. Turn the ignition ªoffº.
2. Disconnect the J2 (WHITE) PCM connector.
3. Using the J39200 DVOM, measure the resistance between
terminals J2±D2 and J2±C8.
Is the resistance within 18 ± 20 ohms?
Go to Step 18Go to Step 10
101. Disconnect the transmission 16±way connector H±53.
2. Using the J39200 DVOM, measure the resistance between
terminal H53±8 and ground.
Is the resistance within 18±20 ohms?
Go to Step 12Go to Step 11
111. Disconnect the transmission adapter case connector M±6.
2. Using the J39200 DVOM, measure the resistance between
terminal M6±4(A) and ground.
Is the resistance within 18±20 ohms?
Go to Step 13Go to Step 14

MANUAL TRANSMISSION7B±13
(4JX1)
225RW020
5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.
220RS006
6. Install three flywheel under cover (6VE1).

7B±42MANUAL TRANSMISSION
5. Using a thickness gauge, measure the clearance
between the 4th block ring back and gear spline
end.
Standard: 0.75 ± 1.65 mm (0.030 ± 0.065 in)
226RW064
6. Check the braking effect of the block ring. Turn
the block ring in one direction while pushing it to
the gear cone. Check that the ring locks. If it does
not lock, replace the block ring.
226RW060
7. Install the needle roller bearing.
2. Reassemble the mainshaft assembly.
NOTE: Apply all parts with engine oil before installing
them.3. Inspect block ring
1. Using a thickness gauge, measure the clearance
between the synchronizer ring back and gear
spline end.
Gear
Standard Clearanse
1st0.80 ± 1.60 mm (0.032 ± 0.063 in)
2nd0.65 ± 1.75 mm (0.026 ± 0.069 in)
3rd0.75 ± 1.65 mm (0.030 ± 0.065 in)
226RW105
2. Turn the synchronizer ring in one direction while
pushing it to the gear cone. Check that the ring
locks.
226RW106

7C±8CLUTCH
Diagnosis
ConditionPossible causeCorrection
DraggingFluid leakage.Repair
Air in hydraulic line.Bleed
Master cylinder and slave cylinder
seals worn. Replace master cylinder.
Replace slave cylinder seals.
Driven plate warped.Replace driven plate.
Diaphragm spring weakened or tip of
fingers worn. Replace pressure plate
Driven plate sticking on splines.Lubricate with grease or replace.
Clutch spline worn. Repair
Release bearing worn or damaged.Replace release bearing.
SlippingDriven plate facing worn or
oil±soaked.Replace driven plate and check for
leaks.
Diaphragm spring weakened.Replace pressure plate.
Pressure plate or flywheel warped.Correct or replace.
Master cylinder and slave cylinder
seals worn.Replace master cylinder.
Replace slave cylinder seals.
ChatteringEngine mounts loose or damaged.Tighten or replace.
Driven plate facing warped.Replace driven plate.
Surface of facing hardened.Replace driven plate
Driven plate facing oil soaked. Replace driven plate and check for
leaks.
Damper springs weakened or
broken. Replace.
Pressure plate or flywheel warped.Correct or replace.
NoisyReplace bearing binding.Correct, or replace if damaged, and
lubricate.
Replace bearing worn or damaged. Replace release bearing.
Release bearing poorly lubricated. Lubricate.
Pilot bearing worn.Replace pilot bearing.
Damper springs weakened or
broken.Replace driven plate.
Rivets of driven plate exposed.Replace driven plate.
Replace driven plate.Hydraulic line blocked.Clean out or replace.
Master or slave cylinders binding.Repair or replace as needed.

7C±14CLUTCH
Release Bearing
201RS011
1. Visually check the release bearing for excessive play,
noise and breakage.
2. If any of these conditions are discovered, the release
bearing must be replaced.
3. When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.
201RW010
Legend
(1) Wire Ring
(2) Pressure Plate Assembly
(3) Wedge Collar
(4) T/M Side
(5) Release Bearing
(6) Engine Side
Wedge Collar
201RS013
1. Visually check the surfaces of the wedge collar
making contact with the release bearing for excessive
wear and damage.
2. Replace any exhibiting excessive wear or damage.
Shift Fork
201RS014
1. Visually check the surfaces of the shift fork making
contact with the release bearing for excessive wear
and damage.
2. Remove any minor stepping or abrasion from shift
fork with an oil stone.
3. Replace any exhibiting excessive wear or damage.

7C±20CLUTCH
2. Adjust clutch padel adjusting bolt by backing it out
half a turn, and measure the clearance (
)
between the clutch pedal arm and the adjusting
bolt.
203RW010
Legend
(9) Bracket
(10) Clutch Pedal Adjusting Bolt
(11) Lock Nut
(12) Clutch Pedal Arm
3. Lock the lock nut.
Clutch Switch and Clutch Pedal Clearance (
)
0.5 mm ± 1.5 mm (0.020 in ± 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm ± 15 mm (0.20 in ± 0.59 in)
203RW004
6. Clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the
wheels.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:

Hydraulic circuit for fluid leakage or air in circuit.

Clutch disc warped.

Diaphragm spring weakened or tip of fingers worn.

Driven plate sticking on sprines.

Release bearing worn or damaged.

Master cylinder and slave cylinder worn.
203RW007
Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height

LIGHTING SYSTEM8A–29
Light NameRated PowerNumber of
BulbsLens ColorRemarks
Headlight60w/55w2WhiteHalogen
FrontTurn signal light21w2Whitecombination
lightClearance light5w2Amber
FRT fog light55w2WhiteHalogen
Taillight/Stoplight5w/21w2Red
RearBumperTurn signal light21w2Ambercombination
lightTaillight/Stoplight5w/21w2RedBodyTurn signal light21w2Amber
Backup light21w2White
RR fog light21w2Red
Side turn signal light5w2Amber
License plate lightBumper5w2White
Body5W1White
High mount stoplight——RedLED
Map light5w2White
Dome light10w1White
Luggage room light8w1White
Courtesy light3.8w2White
A/C SW60mA1
RR defogger SW0.84w1
Mirror defogger SW0.84w1
FRT fog light SW0.7w1
RR fog light SW0.7w1
Cruise (Set)1.4w1Meter
Cruise (Main)1.4w1Meter
Check trans3w1Meter
Anti-theft3w1Warning box
Turn signal1.4w2Meter
Golw1.4w1Meter
Water sedimenter1.4w1Meter
Indicator/High beam1.4w1MeterWarning
lightABS1.4w1Meter
Check engine1.4w1Meter
Low fuel1.4w1Meter
4WD1.4w1Meter
Oil Pressure1.4w1Meter
Brake system1.4w1Meter
Charge1.4w1Meter
Seat belt2w1Meter
A/T shift position0.91w7Meter
A/T oil temp3w1Meter

8DÐ8 WIRING SYSTEM
5. The wiring harness between engine and chassis
should be long enough (2). Tension of the wire (1) may
causes chafing or damage due to various vibrations.
Splicing Wire
1. If the harness is taped, remove the tape. To avoid wire
insulation damage, use a sewing Òseam ripperÓ
(available from sewing supply stores) to cut open the
harness.
If the harness has a black plastic conduit, simply pull
out the desired wire.
2. Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire later
if you decide to cut more wire off to change the location
of a splice. You may have to adjust splice locations to
make certain that each splice is at least 1Ð1/2Ó
(40 mm) away from other splices, harness branches,
or connectors.
3. When replacing a wire, use a wire of the same size as
the original wire.
Check the stripped wire for nicks or cut stands. If the
wire is damaged, repeat the procedure on a new
section of wire. The two stripped wire ends should be
equal in length.
4. Select the proper clip to secure the splice.
To determine the proper clip size for the wire being
spliced, follow the directions included with your clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them
between your thumb and forefinger as shown in the
figure.
The center the spline clip (1) under the stripped wires
and hold it in place.cOpen the crimping tool to its full width and rest one
handle on a firm flat surface.
cCenter the back of the splice clip on the proper anvil
and close the crimping tool to the point where the back
of the splice clip touches the wings of the clip.
cMake sure that the clip and wires are still in the correct
position. Then, apply steady pressure until the
crimping tool closes as shown in the figure.
2
11

WIRING SYSTEM 8DÐ399
Diagnosis
Diagnosis Procedure
1. Check to see if the battery voltage is normal.
2. Check to see if the fuse is normal.
3. Replace the antiÐtheft & keyless entry control unit with one reserved for test. If a trouble recurs even after replacing
the control unit, find out the cause of the trouble by referring to ÒSystem check procedureÓ and the following list.
ITEM MALFUNCTION POSSIBLE CAUSE DETECTING METHOD REMARKS
ANTIÐTHEFT
indicator light
does not flash
ANTIÐTHEFT
indicator light
does not turn off.
(Steadily on)
When door is
opened by pulling
up locking knob,
alarm does not
operate
Alarm does not
stop. Indicator light
does not change
to fully ON
condition, or does
not come on at
all.Burnt out indicator
light bulb possible.
Refer to ÒConnector
check tableÓ in this
system.
Refer to ÒConnector
check tableÓ in this
system.
Refer to ÒConnector
check tableÓ in this
system.
Refer to ÒConnector
check tableÓ in this
system.
Refer to ÒConnector
check tableÓ in this
system.
Refer to ÒConnector
check tableÓ in this
system. Defective contact of door switch,
or open circuit in door switch
wiring.
Short circuit in the detect switch.
Engine hood, doors and tailgate
are not fully closed and locked.
Defective door switch, or short
circuit in switch wiring.
Defective tamper switch, or short
circuit in wiring.
Defective lock switch, or short
circuit in wiring.
Defective engine hood switch, or
short circuit in wiring.
Defective tailgate switch, or short
circuit in wiring.
Defective control unit.
Poor contact of lock switch, or
open circuit in wiring.
Broken wire in wiring to headlight
and horn, or a blown fuse.
Defective contact of detect
switch, or damaged switch wiring.With door open, dome light and
courtesy light do not come on.
Check the control unit connector.
Check to see if doors are closed
and locked.
Dome light and courtesy light
remain lit on after closing doors.
Check the control unit connector.
Check the control unit connector.
Check the control unit connector.
Luggage room light remains lit
after closing tailgate.
Check alarm operation (See No.
46 of ÒSystem check procedureÓ),
possible cause is a poor contact
of lock switch of an open circuit in
wiring.
Check to see if headlights go out.
Check the control unit connector.
Check the control unit connector. A
C
D
E B

8DÐ400 WIRING SYSTEM
ITEM MALFUNCTION POSSIBLE CAUSE DETECTING METHOD REMARKS
Even when door
unlocked with
key, alarm
operates.
Alarm does not
operate even with
tailgate open.
Even when
tailgate is opened
with key, alarm
does not stop.
Even when
engine hood is
opened with
remote release,
alarm does not
operate
Even when
starter switch is
turned, alarm
does not stop
Indicator light
continues
flashingRefer to ÒConnector
check tableÓ in this
system.
Refer to ÒConnector
check tableÓ in this
system.
Refer to ÒConnector
check tableÓ in this
system. Defective contact of detect
switch, or damaged switch wiring.
Door detect switch is assembled
to wrong door.
Defective contact of tailgate
switch, or defective wiring.
Defective contact of tailgate
detect switch, or damage wiring.
Damaged engine hood switch or
wiring.
Defective contact of starter
switch.
Damaged door switch, or a short
circuit in wiring.
Damaged tamper switch, or a
short circuit in wiring.Check the control unit connector.
When key is turned to lock
position, alarm stops.
When luggage room light switch
is turned on with tailgate open,
luggage room light does not
come on.
Check the control unit connector.
With starter switch turned to
ÒACCÓ position, audio, cigarette
lighter and door mirrors (on
ÒACCÓ circuit) do not operate.
After closing door, dome light and
courtesy light remain on.
Check the control unit connector. F
G
H
I
J
K