clock ISUZU TROOPER 1995 User Guide

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN 3F4-15
Fig. 3F4-35
6. Steering column cover
7. Combination switch and SRS coil assembly
•
Disconnect the wiring harness connectors
located under the steering column.
• Remove the combination switch assembly
with SRS coil (Fig. 3F4-36).
Fig. 3F4-36
NOTE:
SRS coil is a part of combination switch
assembly, which can not be replaced singly.
Therefore, be sure not to remove the SRS coil
from the combination switch assembly.
8. Snap ring
9. Cushion rubber
10. Shift lock cable (For A/T)
11. Lock
cylinder assembly
• Disconnect the starter switch harness
connector located under the steering column.
12. Steering column assembly
•
Apply a setting mark across the universal joint
and steering shaft to reassemble the parts in
their original position (Fig. 3F4-37). Fig.
3F4-37
NOTE:
A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft
universal joint.
B INSTALLATION
12. Steering column assembly
• Align the setting marks on the universal joint
and steering shaft made during removal.
•
Tighten the steering column fixing bolt (dash
panel) to the specified torque.
Torque
N-mOb·ft) 19 (14)
• Tighten the steering column fixing bolt (pedal
bracket) to the specified torque.
Torque N·m(lb·ft) 17 (13)
• Tighten the universal joint to the specified
torque.
Torque
N-m(lb·ft)
11. Lock cylinder assembly
10.
Shift lock cable (For A/T)
9. Cushion rubber
8. Snap ring
25 (18)
7. Combination switch and SRS coil assembly
• After installation of combination switch
assembly, connect the combination switch
wiring harness connector and the SRS 3way
connector located under the steering column.
•
Turn the SRS coil clockwise to full, return
about 3 turns and align the neutral mark
(Fig. 3F4-38).

3F4-16 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN
Alignment mark
Fig. 3F4-38
\fCAUTION:
When turning the SRS coil clockwise to full, stop
turning if resistance is felt. Forced furtherturning
may damage to the cable in the SRS coil.
6. Steering column cover
• When installing the steering column cover, be
sure
to wire (through each harness) as
illustrated so that the harnesses starter
switch,
combination switch and SRS coil may
not catch wiring (Fig. 3F4-39).
Starter switch
harness
Combination switch harness
Inflator module harness
5. Steering wheel
Fig. 3F4-39
• Align the setting marks made when re­
moving.
WCAUTION:
Never apply force to the steering wheel in
direction
ofthe shaft by using a hammer or other
impacttools in an attempt to remove the steering
wheel. The steering
shaft is designed as an
energy absorbing unit.
• Tighten the steering wheel fixing nut to the
specified torque. Torque
N·m (lb·ftl 34
(25)
4. Inflator module
• Support the module and carefully connect the
module connector.
NOTE:
Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead
wire from being pinched.
• Secure the module with one bolt to relieve
weight on the connector wire.
• Tighten bolts to specified sequence as figure
(Fig. 3F4-40).
Torque
N·m (lb-in) 8 (69)
Fig. 3F4-40
3. Driver knee bolster (reinforcement)
2. Steering lower cover
• Install the engine hood opening lever.
1. Front console assembly
• Connect the wiring harness connectors.
• Install the transmission (for M/T) and transfer
control lever knob.
• Connect the yellow 3way SRS connector located
under the steering column.
• Connect the battery "-"terminal cable.
SYSTEM INSPECTION
• Set ignition to "ON" while watching warning
light.
• Light should flash 7 times and then go off. If
lamp does not operate correctly, refer to
Section 9J.
•

48 -16 REAR AXLE
14. Inner bearing outer race (Fig. 48-30)
l®.llnstaller: J-37261
Grip: J-8092
J-8092
J-37261
Fig. 48-30
13. Adjust shim
UEI • Adjustment of drive pinion mounting distance
a 1) Apply gear oil to the inner and outer drive
pinion bearing.
Clean the pinion setting gauge set.
Then
install the gauge set together with
the inner and outer bearings (Fig. 48-31 ).
CD Front pilot J-21777-42
® Stud and nut J-21777-43
@ Rear pilot J-23597-12
@ Gauge plate J-23597-42
CD
Fig. 48-31
~~ 1-•-T_i..::..g_h_te_n_t_h_e_n_u...,t_t_o_t_h_e_s..:..p_e_c_if_ie_d_t-\
.-o_rq....:..._ue_. __
Torque New bearing 2.3 (20)
N-m (lb-in) Used bearing 1.1 (9.6)
2) Clean the side bearing bores. Install the
dial indicator with the discs and arbor (Fig.
48-32).
Install and tighten the bearing
caps to the specified torque.
~~~ Torque N-m (lb·ft) J 108 (80)
--------~----------1®.1 CD Dial indicator J-8001
® Disc (2 pes.) J-21777-86
@ Arbor J-23597-1
@ Gauge plate J-23597-42
Fig. 48-32
3) Set the dial indicator to "0". Place it on the
mounting post of the gauging arbor with
the contact button touching the indicator
pad. Force the dial indicator downward
until the needle has made a half turn
clockwise. Tighten down the dial indicator
in this position (Fig. 48-33).
Fig. 48-33
4) Position the plunger on the gauge plate.
Move the gauging arbor slowly back and
forth and locate the position at which the
dial indicator shows the greatest
defection. At this point, once again set the
dial indicator to "0" (Fig. 48-34).
Repeat
the procedure to verify the "0"
setting.
•

l•!•l REASSEMBLY
21. Differential carrier
20. Outer bearing outer race (Fig. 4C-35)
l"ii\1 Installer: J-24256
~ Grip: J-8092
J-8092
J-24256
Fig. 4C-35
17. Inner bearing outer race (Fig. 48-36)
l®.llnstaller: J-24252
Grip:
J-8092
Fig. 4C-36
16. Adjust shim
I§FI • Adjustment of drive pinion mounting distance
B 1) Apply gear oil to the inner and outer drive
pinion bearing.
Clean
the pinion setting gauge set.
Then
install the gauge set together with
the inner and outer bearings (Fig. 4C-37).
CD Pilot: J-21777-42
® Nut and bolt: J-23597-9
® Gauge plate : J-23597 -7
FRONT DRIVING AXLE 4C -17
CD
Fig. 4C-37
~~I _• _T:.:i:?.g.:.:h.:.:te:.:..n:...:t:.:..:h~e...:.n.:..:u:..:.t,..:.to.::......:.:th..:...e:.....:.:sp:....e:....:c_if_ie_d_t_orr-=-q-ue_. __
Torque New bearing 2.3 (20)
N-m (lb-in)
Used bearing 1.1 (9.6)
2) Clean the side bearing bores. Install the
dial indicator with the discs and arbor (Fig.
4C-38).
Install and tighten the bearing caps
to the specified torque.
1.;-. I Torque N-m (lb·ft) J 98 (72) ~ ~~--~~.---------
CD Dial indicator: J-8001
® Disc (2 pes.): J-23597-8
® Arbor: J-23597-1
@ Gauge plate: J-23597-42
Fig. 4C-38
3) Set the dial indicator to "0". Place it on the
mounting post of the gauging arbor with
the contact button touching the indicator
pad. Force the dial indicator downward
until the needle has made a half turn
clockwise. Tighten down the dial indicator
in this position (Fig. 4C-39)

&A 1-22 ENGINE (V& 3.2L DOHC AND SOHC)
Fig. 6A1-27
Alignment mark on ~ timing belt ~
DOHC " ' on front plate
~~
Alignment mark
_","'
SOHC
DOHC
SOHC
/ Alignment mark on timing belt
Fig. 6A1-28
1) Crankshaft timing pulley 2) RH bank timing pulley 3) Water pump pulley 4) Idler pulley 5) LH bank timing pulley 6) Tension pulley
fig. 6A1-29
5) Turn the crankshaft counterclockwise to
remove the belt slack between the crankshaft
timing
pulley and the RH bank camshaft ,.......,,
timing pulley.
6) Install the belt on the water pump pulley.
7) Install the belt on the idler pulley.
8) Align the alignment mark (white line) on the
timing belt with the alignment mark on the
LH
bank camshaft timing pulley.
If
the belt is difficult to install, turn the
camshaft
pulley slightly counterclockwise.
9) Install crankshaft pulley temporarily and
tighten center bolt by hand (do
not use a
wrench). Turn the crankshaft
pulley clockwise
to give some slack between the crankshaft
timing
pulley and the RH bank camshaft
timing
pulley.
1 0) Install the pusher while pushing the tension
pulley to the belt.
11) Pull out the pin from the pusher.
NOTE:
When reusing the pusher, press the pusher to
retract the rod (1.4 mm piano wire). (Fig. 6A 1-30)
Approx. 100 kg
... Direction for installation
Fig. 6A1-30
,.. ..
•

12) Remove double clips from pulleys. Turn the
crankshaft
pulley clockwise by two turns.
Measure the rod protrusion to ensure
it is
within the standard. (Fig. 6A 1-31)
Standard
mm (in) I 4 - 6 (0.16 -0.24)
Adjusting bolt
Pusher
Fig. 6A1-31
13) If out of standard, remove pusher, loosen
adjusting bolt, and readjust. Repeat from step
11 ).
Tighten adjusting bolt to the specified torque
1~1 Torque N·m (lb·ft) I 42 (31)
11. Pusher
• Tighten bolt to the specified torque.
1~1 Torque N·m (lb·ft) I 19 (14)
10. Timing belt cover
• Remove crankshaft pulley that was installed in
step
9.
• Tighten bolts to the specified torque.
~~~ Torque N·m (lb·ft) I 17 (12)
9. Oil cooler hose
• Tighten oil cooler hose bracket bolts to the
specified torque.
~~~ Torque N·m (lb·ft) I 22 (16)
8. Crankshaft pulley
l"iQ\1 • Using special tool J-8614-01, hold the
~ crankshaft pulley.
•
Tighten center bolt to the specified torque.
1~1 Torque N·m (lb·ft) 167 (123)
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-23
7. Fan pulley assembly
• Tighten fixing bolt to the specified torque.
~~~ Torque N·m (lb·ft) 22 (16)
6. Generator drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
5. Air Conditioning drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
4. Power steering pump drive belt
• Engage and adjust.
• Refer to Section 68 "Drive belt adjustment".
3. Cooling fan assembly
• Tighten nuts to the specified torque.
~~~ Torque N·m (lb·in) I 8 (69)
2. Radiator upper fan shroud
1. Air cleaner assembly

6C -10 ENGINE FUEL
Adjustment of pedal stroke
Manual Transmission:
• Rotate counterclockwise to loosen the stopper
bolt sufficiently.
• Fully depress the pedal and hold it there hand.
Next, rotate the stopper bolt until it hits the
stopper of pedal bracket. Then, lock the stopper
bolt there.
Automatic Transmission:
• Rotate counterclockwise to loosen the kickdown
switch sufficiently.
• Fully depress the pedal and hold it there hand.
Rotate
the switch clockwise and then rotate
further by 1/2 turn from the position where the
switch clicks. Lock the switch there.
• Step on the accelerator pedal and make sure that
you can hear clicking sound at the full stroke
position.
AIR CLEANER FILTER
EJ REMOVAL
1. Air hose
2. Air cleaner cover
3. Air Cleaner Filter
(Fig.6C-12), (Fig.6C-13)
2. Air cleaner cover
3. Air Cleaner filter
(DOHC)
Fig. 6C-12
2. Air clearner cover
3.
Air Cleaner filter
(SOHC)
Fig. 6C-13
~ INSPECTION
Check the Air Cleaner filter for damage or dust clog­
ging. Replace if it is damaged, or clean if it is clogged.
Cleaning method
Hit the Air Cleaner filter gently with care not to dam­
age the paper filter, or clean the element by blowing
with compressed air of about 49kPa (71 psi) from the
clean side if it is extremely dirty.
Fig. 6C-14
8 INSTALLATION
3. Air Cleaner filter
2. Air cleaner cover
• Meet the cover to the body completely, then
clamp it with the clip.
1. Air cleaner hose
•

602 -12 CRANKING SYSTEM
23. Pinion
Disassembling pinion
• Holding the pinion shaft, push pinion toward
the center bracket.
• Turn the pinion clockwise or counterclockwise
by one tooth of spline, then pull offthe pinion.
(Fig. 602-14)
To center bracket side
Pinion
Fig. 602-14
24. Thrust washer (2)
25. Center bracket
26. Pinion shaft (Fig. 602-15)
Center bracket ( P)
Fig. 602-16
~ INSPECTION AND REPAIR
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. (Fig.
602-16)
mm(in)
Standard Limit
33(1.30) 32 (1.26)
•
Fig. 602-16
Check
for continuity between commutator and
segment.
Replace commutator if there is no con­
tinuity (i.e., disconnected). (Fig. 602-17)
Fig. 602-17
• Check for continuity between commutator and
shaft.
Also, check for continuity between commu­
tator and armature core,armature core and shaft.
Replace commutator if there is continuity (i.e.,
internally grounded). (Fig. 602-18)
Fig. 602-18
•

CRANKING SYSTEM 602-17
MAIN DATA AND SPECIFICATIONS
Model HITACHI GD002350
Rating
Voltage v 12
Output kw 1.4
Time sec 30
Number of teeth of pinion
9
Rotating direction (as viewed
from pinion) Clockwise
Weight (approx.)
N 34
No-load characteristics
Voltage/current V/A
11/90 or less
Speed rpm 2700 or more
Load characteristics
Voltage/current V/A
8.4/250
Torque N·m (lb·in) 7.3 (64) or more
Speed rpm 1200 or more
Locking characteristics
Voltage/current V/A
3/750 or less
Torque N·m (lb·ft) 19 (14) or more

603 -12 CHARGING SYSTEM
Part Number (Nippon Denso) 101211-2020 1 00211-9730
Model ACGH03 ACJQ17
Rated
voltage v 12 12
Rated output A 60 75
Rotating direction
Clockwise Clockwise (As
viewed from pulled)
Pulley
effective diameter mm (in) 50 (1.97) 50 (1.97)
Weight N (lb) 33 (25) 44 (33)
M{f (STD) AfT (STD) M!T (OPTION)
•