ISUZU TROOPER 1995 Workshop Manual

Supplemental Restraint System 9J-127
SRS COIL ASSEMBLY
WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED INFLATOR
MODULE{AIR
BAG). AFTER DEPLOYMENT, THE INFLATOR MODULE{AIR BAG) SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO
THE SKIN AND EYES. MOST OF THE POWDER ON THE INFLATOR MODULE (AIR BAG )IS
HARMLESS.
AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED
INFLATOR MODULE {AIR BAG ), AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE INFLATOR MODULE {AIR BAG ), MAKE SURE THE BAG AND TRIM
COVER
ARE POINTED AWAY FROM YOU. NEVER CARRY INFLATOR MODULE {AIR BAG )BY THE WIRES OR
CONNECTOR ON
THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG
WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE INFLATOR MODULE (AIR
BAG ) ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE INFLATOR
MODULE (AIR BAG) FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE
IS PROVIDED TO
ALLOW THE INFLATOR MODULE { AIR BAG ) TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL
DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE:
In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any
other damage due to excessive heat.
If the coil has been damaged, replace it.
REMOVAL ~------------------------------------------,
1. Disable the SRS. (Refer to "Disabling the SRS"
in this section.)
2. Remove the transmission knob(for
MIT) and
transfer
control knob.
3. Remove front console assembly and disconnect
the wiring harness connector.
4. Remove the steering lower cover and engine
hood opening
lever.
5. Remove inflator module (Air Bag) from steering
wheel by removing four bolts. Lift inflator module
(Air Bag) out of steering wheel.
6. Disconnect connector and remove inflator
module (Air Bag).
7. Disconnect horn lead
8. Remove steering wheel attachment nut.
9. Apply a setting mark across the steering wheel
and shaft so parts can be reassembled in their
original position.
10. Move the tires to the straight ahead position
before removing the steering
wheel and install
steering wheel puller onto steering wheel and
remove steering
wheel with J-29752.
11. Feed wiring through the wheel and remove
wheel.
CAUTION:
NEVER APPLY FORCE TO THE
STEERING WHEEL IN DIRECTION OF THE SHAFT
BY USING A HAMMER OR OTHER IMPACT TOOLS
~ IN AN ATTEMPT TO REMOVE THE STEERING
WHEEL. THE STEERING SHAFT IS DESIGNED AS
AN ENERGY ABSORBING UNIT.

9J-128 Supplemental Restraint System
12. Remove steering column cover.
13. Disconnect the wiring harness connectors ~
located base of steering column.
14. Remove the combination switch assembly with
SRScoil.
NOTE: SRS
coil is a part of combination switch
assembly, which
cannot be replaced individually.
Therefore, be sure not to remove the
SRS coil from the
combination switch assembly.
INSTALLATION
1. Install the combination switch assembly with
SRScoil.
2. Connect the wiring harness connector located In
base of steering column.
3. Turn the SRS coil clockwise to full, return about
3 turns and align the neutral mark.
CAUTION: WHEN TURNING THE SRS COIL
CLOCKWISE TO FULL, STOP TURNING IF
RESISTANCE IS FELT. FORCED FURTHER
TURNING MAY CAUSE DAMAGE TO THE CABLE IN
THE SRS COIL.
4. Install steering column cover.
CAUTION: WHEN INSTALLING THE STEERING
COLUMN COVER, BE SURE TO WIRE (THROUGH ~
EACH HARNESS) AS ILLUSTRATED SO THAT THE
HARNESSES OF STARTER SWITCH,COMBINATION
SWITCH
AND SRS COIL MAY NOT CATCH WIRING.
5. Install the steering wheel and align the setting
marks.
6. Tighten the steering fixing nut to the specified
torque.
Torque : 34N·m(25 lb·ft.).
7. Connect horn lead connector.
8. Connect inflator module to 2-way yellow wiring
harness connector.
9. Install inflator module into steering wheel and
torque fasteners.
NOTE: Always replace inflator module {Air Bag)
fasteners with new fasteners. Never reuse old fasteners.
Torque: 8N·m(69 lb·ln.)
10. Install the steering lower cover and engine hood
opening lever.
11. Install front console assembly and connect the
wiring harness connector.
12. Install the transmission knob{for M/T) and
transfer control knob. ~
13. Enable the SRS (Refer to "Enabling the SRS" in
this section.).
•

Supplemental Restraint System 9J-129
STEERING COLUMN
WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED INFLATOR
MODULE{AIR
BAG). AFTER DEPLOYMENT, THE INFLATOR MODULE{AIR BAG) SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO
THE SKIN AND EYES. MOST OF THE POWDER ON THE INFLATOR MODULE (AIR BAG )IS
HARMLESS.
AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED
INFLATOR MODULE (AIR BAG ), AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE INFLATOR MODULE {AIR BAG ), MAKE SURE THE BAG AND TRIM
COVER
ARE POINTED AWAY FROM YOU. NEVER CARRY INFLATOR MODULE (AIR BAG )BY THE WIRES OR
CONNECTOR ON
THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG
WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE INFLATOR MODULE (AIR
BAG ) ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE.NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE INFLATOR
MODULE {AIR
BAG) FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE
IS PROVIDED TO
ALLOW THE INFLATOR MODULE (AIR BAG) TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL
DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE:
In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any
other damage due to excessive heat.
If the coil has been damaged, replace it.
REMOVAL ~--------------------------~
1. Disable the SRS. (Refer to "Disabling the SRS "
in this section.)
2. Remove the transmission knob(for MIT) and
transfer
control knob.
3. Remove front console assembly and disconnect
the wiring harness connector.
4. Remove the steering lower cover and engine
hood opening
lever.
5. Remove inflator module (Air Bag) from steering
wheel by removing four bolts. Lift inflator module
(Air Bag) out of steering wheel.
6. Disconnect 2-way yellow connector and remove
inflator module (Air Bag).
7. Disconnect horn lead connector
8. Remove steering wheel attachment nut.
9. Apply a setting mark across the steering wheel
and shaft so parts can be reassembled in their
original position.
1
0. Move the tires to the straight ahead position
before removing the steering
wheel, and install
steering wheel puller onto steering wheel and
remove steering
wheel with J-29752.
11. Feed wiring through the wheel and remove
wheel.
y
®

9J .. 130 Supplemental Restraint System
CAUTION: NEVER APPLY FORCE TO THE
STEERING WHEEL IN DIRECTION OF THE SHAFT
BY USING A HAMMER OR OTHER I~PACT TOOLS
IN AN ATTEMPT TO REMOVE THE STEERING
WHEEL. THE STEERING SHAFT IS DESIGNED AS
AN ENERGY ABSORBING UNIT.
12. Remove steering column cover.
13.
Disconne~t the wiring harness connectors
located base of steering column.
14. Remove the combination switch assembly with
SRScoil.
NOTE: SRS
coil is a part of combination switch
assembly,
which cannot be replaced individually.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly.
15. Remove snap ring.
16. Remove cushion rubber.
17. Disconnect shift
lock cable(For AfT)
18. Disconnect the starter switch harness connector.
Located base of steering column.
19. Remove steering
lock cylinder assembly.
20. Apply a setting mark across the universal joint
and steering shaft to reassemble the parts
in ~
their original position. ~
21. Remove steering column assembly.
NOTE: A setting mark can be easily made if the shaft
is with draw a little by loosening the steering shaft
universal joint.
INSTALLATION
1. Install steering column assembly and align the
setting marks on the universal joint and steering
shaft made during removal.
2. Tighten the steering column fixing bolts( dash
panel side) to the specified torque.
Torque:
19N·m(14 lb·ft.).
3. Tighten the steering column fixing bolts( Pedal
bracket) to the specified torque.
Torque:
17N·m(13 lb·ft.).
4. Tighten the universal joint to the specified
torque.
Torque:
25N·m(181b·ft.).
5. Install steering lock cylinder assembly.
6. Connect shift lock cable(For AfT)
7. Install cushion rubber.
8. Install snap ring.
9. Install the combination switch assembly with
SRScoil.

1 o. Connect the wiring harness connector located
base of steering column.
11. Turn the SRS coil clockwise to full, return about
3 turns and align the neutral mark.
CAUTION: WHEN TURNING THE SRS COIL
CLOCKWISE TO FULL, STOP TURNING IF
RESISTANCE IS FELT. FORCED FURTHER
TURNING MAY CAUSE DAMAGE TO THE CABLE IN
THE SRS COIL.
12. Install steering column cover.
CAUTION: WHEN INSTALLING THE STEERING
COLUMN COVER,
BE SURE TO WIRE {THROUGH
EACH HARNESS) AS ILLUSTRATED SO THAT THE
HARNESSES OF STARTER SWITCH,COMBINATION
SWITCH
AND SRS COIL MAY NOT CATCH WIRING.
13. Install the steering wheel and align the setting
marks.
14. Tighten the steering fixing nut to the specified
torque.
Torque: 34N·m(25 lb·ft.).
15. Connect horn lead connecor.
16. Connect inflator module to
2-way yellow wiring
harness connector.
17.
Install inflator module into steering wheel and
torque fasteners.
Torque: 8N·m(69 lb-in.)
18. Install the steering lower cover and engine hood
opening lever.
19.
Install front console assembly and connect the
wiring harness connector.
20.
Install the transmission knob(for M/T) and
transfer control knob.
21. Enable the
SRS (Refer to "Enabling the SRS" in
this section.).
Supplemental Restraint System 9J-131

9J-132 Supplemental Restraint System
PASSENGER INFLATOR MODULE
WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED INFLATOR ~
MODULE(AIR BAG). AFTER DEPLOYMENT, THE INFLATOR MODULE(AIR BAG) SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO
THE SKIN AND EYES. MOST OF THE POWDER ON THE INFLATOR MODULE (AIR BAG )IS
HARMLESS. AS
A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED
INFLATOR MODULE (AIR BAG ), AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE INFLATOR MODULE (AIR BAG ), MAKE SURE THE BAG AND TRIM
COVER
ARE POINTED AWAY FROM YOU. NEVER CARRY INFLATOR MODULE (AIR BAG )BY THE WIRES OR
CONNECTOR ON
THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG
WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE INFLATOR MODULE (AIR
BAG ) ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE.
REMOVAL
1. Disable the SRS. (Refer to "Disabling the SRS
"
in this section.)
2. Remove the transmission knob(for MfT) and
transfer control knob.
3. Remove front console assembly and discon-
nect the wiring harness connector.
4. Remove lower cluster.
5. Remove glove box assembly.
6. Remove instrument lower cover.
7. Remove passenger side knee bolster rein-
forcement
8. Disconnect SRS module harness connector.
9. Remove SRS module fixing nuts.
10. Remove passenger SRS module.
INSTALLATION
1. Install passenger SRS module.
2. Install SRS module fixing nuts and tighten the
specified torque.
Torque: 6N·m(52 lb·ln.).
3. Connect SRS module harness connector.
4. Install passenger side knee bolster reinforce-
ment
5. Install instrument lower cover.
6. Install glove box assembly.
7. Install lower cluster.
8. Install front console assembly and connect the
wiring harness connector.
9. Install the transmission knob(for MfT) and
transfer control knob.
1
o. Enable the SRS (Refer to "Enabling the SRS" ~
in this section.). ,...,......,..
IIIII

Supplemental Restraint System 9J-133
SPECIFICATION
FASTENER TIGHTENING SPECIFICATION
Driver Inflator Module fixing bolt ........................................................ 8N·m(69 lb·in.)
Steering wheel fixing bolt ............................................................. 34N·m(25 lb·ft.)
Steering column(dash panel side fixing bolts) ........................................... 19N·m(14 lb·ft.)
(Pedal bracket fixing bolt) .............................................. 17N·m(13 lb·ft.)
(Universal joint fixing bolt) ............................................. 25N·m(18 lb·ft.)
Discriminating forward sensor LH fixing bolts ........................................... 29N·m(22 lb·ft.)
Discriminating forward sensor RH fixing bolts ........................................... 29N·m(22 lb·ft.)
Dual pole
arming sensor fixing bolts ................................................... 25N·m(19 lb·ft.)
Passenger Inflator module fixing nuts ................................................... 6N·m(52 lb·in.)

MEMO

BODY 10-1
SECTION 10
BODY
\V CAUTION : When fasteners are removed, always reinstall them at the same location from which they
were removed. If a fastener needs to be replaced, use the correct part number fastener for
that application. If the correct part number fastener is not available, a fastener of equal size
and strength (or stronger)
may be used. Fasteners must be used when installing fasteners
that require it. If the above conditions are not followed, parts of system damage could result.
CONTENTS
General Description ................. 10-2 Front Door Weatherstrip ......... 10-53
On-Vehicle Service .................. 10-3 Rear Door Weatherstrip .......... 10-54
Body Dimension .................. 10-3 Front Door Seal Finisher ......... 10-54
Upper Body .................... 10-3 Rear Door Seal Finisher .......... 10-54
Front Section ................... 10-7 Door Mirror .................... 10-55
Room Section .................. 10-9 Body Side ....................... 10-56
Rear Section ................... 10-14 Interior Trim Panels ............. 10-56
Side Body ..................... 10-16 Center Pillar and Roof Side Trim
Window Glass .................. 10-19 Cover (L·W·B only) .............. 10-61
Front End ........................ 10-23 Roof Side Trim Cover (S·W·B only) . 10-62
Dash Side Trim Panel ............ 10-23 Front Pillar Trim Cover ........... 10-63
Assist Grip ..................... 10-23 Center Pillar Assist Grip .......... 10-63
Consoles ...................... 10-24 Assist Grip ..................... 10-63
Instrument Panel Assembly ....... 10-25 Fuel Filler lid Opener Cable ....... 10-64
Cross Beam Assembly ........... 10-30 Fuel Filler Door ................. 10-65
Doors ........................... 10-32 Rocker Protector (Without Wheel
Front Door Assembly ............ 10-32 Opening Extension) ............. 10-66
Rear Door Assembly ............. 10-32 Wheel Opening Extension
Door Strikers ................... 10-33 and Rocker Protector Assembly ... 10-67
Door Check Arm Assembly Mud Flaps (With Wheel Opening
(Front & Rear) .................. 10-34 Extension) ..................... 10-69
Front Door Trim Panel ........... 10-35 Ventilation Assembly ............ 10-70
Rear Door Trim Panel ............ 10-38 Quarter Flipper Glass Assembly
Door Wood Panel Assembly ...... 10-40 (S·W·B) ........................ 10-71
Front Window Regulator, Glass Rear End ........................ 10-72
and Glass Run .................. 10-41 Tailgate Assembly (LH) .......... 10-72
Rear Window Regulator and Tailgate Assembly (RH) .......... 10-73
Glass ......................... 10-43 Tailgate Strikers ................ 10-75
Front Door Lock Assembly ....... 10-45 Tailgate Trim Panel (LH) .......... 10-75
Rear Door Lock Assembly ........ 10-46 Tailgate Trim Panel (RH) .......... 10-76
Front Outside Handle and Tailgate Lock Assembly (LH) ...... 10-77
Door Lock Cylinder .............. 10-47 Tailgate Lock Assembly (RH) ...... 10-78
Rear Outside Handle ............. 10-48 Tailgate Inside Lock Knob ........ 10-79
Rear Door Fixed Glass and Tailgate Outside Handle and/or
Glass Run ...................... 10-49 Tailgate Lock Cylinder ........... 10-80
Door Inside Lock Knob ........... 10-50 Tailgate Stopper Assembly ....... 10-81
Door Inside Handle .............. 10-50 Tailgate Dove-tail ............... 10-81
Rear Door Inside Lock Knob Link .. 10-51 Tailgate Dove-tail Strikers ........ 10-82
Front Door Sash Moulding ....... 10-51 Tailgate Frame Cover (LH) ........ 10-82
Rear Door Moulding ............. 10-52 Tailgate Frame Cover (RH) ........ 10-83
Front Door Waist Seal ........... 10-52 Tailgate Sash Trim Cover ......... 10-83
Rear Door Waist Seal ............ 10-53 Tailgate Outer Weatherstrip ...... 10-84

10-2 BODY
Tailgate Center Weatherstrip ...... 10-84 Sun Roof Glass ................... 10-113
Tailgate Main Weatherstrip ....... 10-85
Spare Tire Carrier
............... 10-85
Sun Roof Deflector ................ 10-114
Sunshade ....................... 10-115 ~
Seats ........................... 10-86 Sun Roof Frame Complete
Front Seat Assembly ............ 10-86 Assembly ...................... 10-116
Rear Seat Assembly ............. 10-96 Sun Roof Drain Hose ............ 10-119
Rear Seat Foot Rest (L·W·B) ...... 10-101 Rear Air Deflector ............... 10-122
Luggage Floor Box (L·W·B) ........... 10-101 Roof Moulding ................. 10-124
Rope Hook Set ................... 10-102 Stationary Glass .................. 10-127
Seat
Belt .......................... 10-103 Windshield ..................... 10-127
Front Seat Belt ................... 10-103 Rear Quarter Side Glass .......... 10-130
Front Seat Buckle Assembly ........ 10-105 Tailgate Glass .................. 10-132
Rear Seat Belt .................... 10-106 Child Restraint ................... 10-134
Reat Center Seat Belt (S·W·B) ....... 10-108 Child Seat Tether Anchor Bracket .. 10-134
Rear Center Seat Belt/Buckle Key ............................ 10-135
Assembly ...................... 10-108 Key
Coding .................... 10-135
Rear Seat Lock Assembly .......... 10-109 Key Styles ..................... 10-135
Rear Seat Striker ................. 10-110 Main Data and Specifications ......... 10-136
Roof ............................ 10-111 Torque Specifications .............. 10-136
Headlining ....................... 10-111 Special Tools ....................... 10-146
GENERAL DESCRIPTION
This section describes major items of the removal,
installation
and servicing procedures pertaining to
TROOPER body. Each servicing instruction is
applicable to all models of TROOPER, unless
otherwise specifically mentioned. For those
differing by specific models from the common
procedures, they are detailed for each model.
..