ignition ISUZU TROOPER 1995 User Guide

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN 3F4-7
COMBINATION SWITCH REPLACEMENT
Fig. 3F4-13
E) REMOVAL
Preparation: • Turn the steering wheel so that the
vehicle's wheels are pointing straight
ahead.
W CAUTION: •
Turn the ignition switch to "LOCK".
•
Disconnect the battery "-" terminal
cable, and wait at least 5 minutes.
• Disconnect the yellow 3way SRS
connector located under the steering
column.
The wheels ofthe vehicle must be straight ahead
and
the steering column in the "LOCK" position
before disconnecting the steering wheel. Failure
to do so will cause the coil assembly to become
uncentered
which will cause damage to the coil
assembly.
1.
Front console assembly
•
Remove the transmission (for M{f) and
transfer control lever knob.
• Disconnect the wiring harness connectors.
2. Steering lower cover
• Remove the engine hood opening lever.
3. SRS module (Fig.3F4-14 and 15)
• Loosen the inflator module fixing bolt from behind
the steering
wheel assembly using a TORxe driver
or
equivalent until the inflator module can be
released from steering assembly.
•
Disconnect the yellow 2way SRS connector
located behind the inflator module.
3
Removal steps
1. Front console assembly
2. Steering lower cover
3.1nflator module
4. Steering wheel
5. Steering column cover
6. Combination switch and
SRS coil assembly
Installation steps
To install, follow the removal
steps in the reverse order.
Fig. 3F4-14
Fig. 3F4-15

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN 3F4-9
B INSTALLATION
6. Combination switch and SRS coil assembly
•
After installation of combination switch as­
sembly, 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.3F4-20).
Alignment mark
Fig. 3F4-20
WcAUTION:
When turning the SRS coil clockwise to full, stop
turning if resistance is felt. Forced further turning
may damage to the cable in the SRS coil.
5. 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. 3F4-21 ).
Starter switch
harness
Combination switch harness
Inflator module harness
Fig. 3F4-21
4. Steering wheel
• Align the setting marks made when re­
moving.
W 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.
• Tighten the steering wheel fixing nut to the
specified torque.
Torque
N·m (lb-ft) 34 (25)
3. SRS 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. 3F4-22).
Torque
N·m (lb·in) 8 (69)
2. Steering lower cover
• Install the engine hood opening lever.
1. Front console assembly
• Install
the transmission (for MfT) and transfer
control lever knob.
• Install the wiring harness connectors.
• Connect the battery "-"terminal cable.
• 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.
Fig. 3F4-22

3F4-10 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN
LOCK CYLINDER REPLACEMENT
5
i
;;
9 ®
Fig. 3F4-23
E) REMOVAL
4
3
1
Removal steps
1. Front console assembly
2. Steering lower cover
3.1nflator module
4. Steering wheel
5. Steering column cover
6. Combination switch and
SRS coil assembly
7. Snap ring
8. Cushion rubber
9. Shift lock cable (for AfT)
10. Lock cylinder assembly
Installation steps
To install, follow the removal
steps in the reverse order.
• Disconnect the yellow 2way SRS connector
located behind the inflator module.
Preparation:
• Turn the steering wheel so that the
vehicle's wheels are
pointing
straight ahead.
4. Steering wheel
• Turn the ignition switch to "LOCK".
•
Disconnect the battery"-" terminal
cable, and wait at least 5 minutes.
• Disconnect the yellow 3way SRS
connector located under the steering
column.
• Apply a setting mark across the steering
wheel and
shaft so parts can be reassembled
in
their original position (Fig. 3F4-24)
• Use special tool. Remove the steering wheel.
Move the tires to the straight ahead position
before removing the steering wheel (Fig. 3F4-
25).
W CAUTION: 1®.1 Steering wheel remover: J-29752
The wheels
of the vehicle must be straight ahead
and the steering
column in the "LOCK" position
before disconnecting the steering wheel. Failure
Setting mark
to do so will cause the coil assembly to become
uncentered
which will cause damage to the coil
assembly.
1.
Front console assembly
• Remove the transmission (for Mff) and
transfer
control lever knob.
• Disconnect the wiring harness connectors.
2. Steering lower cover
• Remove the engine hood opening lever.
3. SRS module
• Loosen the inflator module fixing bolt from behind
the steering wheel assembly using a
TORXe driver
or equivalent until the inflator module can be
released from steering assembly. Fig.
3F4-24
•

3F4 -12 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN
Alignment mark
Fig. 3F4-28
\fCAUTION:
When turning the SRS coil clockwise to full, stop
turning if resistance is felt. Forced further turning
may damage to the cable in the SRS coil.
5. 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. 3F4-29).
Starter switch
harness
Combination
switch harness
Inflator module
harness
4. Steering wheel
Fig. 3F4-29
• Align the setting marks made when re­
moving.
\fCAUTION:
Never apply force to the steering wheel in
direction
of the shaft by using a hammer or other
impacttools in an attemptto 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-ft) 34 (25)
3. 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 fixing bolts to specified sequence as
figure (Fig. 3F4-30).
1~1 Torque N·m (lb-in) 8 (69)
Fig.
3F4-30
2. Steering lower cover
• Install the engine hood opening lever.
1. Front console assembly
• Connect the wiring harness connectors.
• Install the transmission (for Mff) 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.

3F4-14 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN
EJREMOVAL
Preparation: • Turn the steering wheel so that the
vehicle's
wheels are pointing straight
ahead.
• Turn the ignition switch to "LOCK".
•
Disconnect the battery "-" terminal
cable,
and wait at least 5 minutes.
• Disconnect the yellow 3way SRS
connector located under the steering
column.
wcAUTION:
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.
1. Front console assembly
• Disconnect the transmission (for MfT) and
transfer
control lever knob.
• Disconnect the wiring harness connectors.
2. Steering lower cover
• Remove the engine hood opening lever.
3. Driver knee bolster (reinforcement)
4. Inflator module (Fig.3F4-32)
• 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 2way SRS connector
located behind the inflator module.
Fig. 3F4-32
\V WARNING
THE INFLATOR MODULE SHOULD ALWAYS BE
CARRIED WITH THE URETHANE COVER AWAY
FROM YOUR BODY AND SHOULD ALWAYS BE
LAID ON A FLAT SURFACE WITH THE URE­
THANE SIDE UP. THIS IS NECESSARY BE­
CAUSE A FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UN­
LIKELY EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONALINJURYMAYRESULT
(FIG.3F4-33).
Fig. 3F4-33
5. Steering wheel
• Apply a setting mark across the steering
wheel and shaft so parts can be reassembled
in their original position (Fig. 3F4-34)
• Use special tool. Remove the steering wheel.
move the tires to the straight ahead position
before removing the steering
wheel (Fig. 3F4-
35).
1®.1 Steering wheel remover: J-29752
Setting mark
Fig. 3F4-34
..

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.
•

SA-2 HYDRAULIC BRAKES
BRAKE SYSTEM DIAGNOSIS
ROAD TESTING THE BRAKES
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and
level roadway. A true test of brake
performance cannot be made
if the roadway is
wet, greasy
or covered with loose dirt so that all
tires do not grip the road equally. Testing will also
be adversely affected if the roadway is crowned so
as to throw the weight of the vehicle toward
wheels on one side or if the roadway is so rough
that wheels tend to bounce. Test the brakes at dif­
ferent vehicle speeds with both light and heavy
pedal pressure; however, avoid locking the wheels
and sliding the tires. Locked wheels and sliding
tires do not indicate brake efficiency, since heavily
braked but turning wheels will stop the vehicle in
less distance than locked wheels. More tire-to-road
friction is present
with a heavily braked turning tire
then
with a sliding tire.
The standard brake system is designed and
balanced
to avoid locking the wheels except at very high
deceleration
levels.
It
is designed this way because the shortest stopping
distance and best
control is achieved without brake
lock-up.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake
Performance
1.
2.
3.
Tires: Tires having unequal contact and grip on
the road
will cause unequal braking. Tires must
be equally inflated, identical in size, and the tread
pattern
of right and left tires must be approxi­
mately equal.
Vehicle loading:
A heavily loaded vehicle requires
more braking effort.
Wheel Alignment: Misalignment of the wheels,
particularly
in regard to excessive camber and
caster,
will cause the brakes to pull to one side.
BRAKE FLUID LEAKS
With engine running at idle and the transmission in
"Neutral", depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls
away with the constant pressure, the hydraulic system
may be leaking.
Check the master cylinder fluid level. While a slight
drop in reservoir level will result from normal lining
wear, an abnormally low level in reservoir indicates a
leak in the system. The hydraulic system may be
leaking internally as well as externally. Refer to
"Master Cylinder Inspection". Also, the system may
appear
to pass this test but still have slight leakage. If
fluid level
is normal, check the vacuum booster
push rod
length. If an incorrect length push rod is
found, adjust
or replace the push rod. Check the
brake
pedal travel and the parking brake adjust­
ment.
When checking the
fluid level, the master cylinder fluid
level
may be low from the "MAX" mark if the front and
rear
linings are worn. This is not abnormal.
WARNING LIGHT OPERATION
When the ignition switch is in the START position,
the
"BRAKE" warning light should glow and go off
when the ignition switch returns to the ON position.
The
following conditions will activate the "BRAKE"
light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the
ignition switch is on.
2. Low fluid level. A low fluid level in the master
cylinder will turn the "BRAKE" light on (Except
Rear
Wheel Antilock Brake System (RWAL)
model).
3. During engine cranking the "BRAKE" light
should
remain on. This notifies the driver that
the warning circuit is operating properly.
4. In the event of a front or rear system malfunc­
tion (RWAL model only).
5. In the event of RWAL malfunction (RWAL
model only. Refer to Section 5A3).
ANTILOCK BRAKE SYSTEM (RWAL or
ABS}
Refer to Section 5A3 or 5A4 for inspection and di­
agnosis procedure of the hydraulic unit.
..

COMBINATION VALVE/P & B
(PROPORTIONING AND BYPASS) VALVE
The combination valve/P & B valve contains two
sections, each serving a different function.
The proportioning section
of the combination valve/
P & B valve proportions outlet pressure to the rear
brakes after a predetermined rear
input pressure has
been reached. This is done to prevent rear
wheel lock­
up on the vehicles with light rear wheel loads.
The valve has a By-pass feature which assures full
system pressure to the rear brakes in the event of a
front brake system malfunction, also full front pressure
is retained in the event
of rear brake malfunction.
HYDRAULIC BRAKES 5A 9
The combination valve has a pressure differential
warning switch which is designed to constantly
compare front and rear brake pressure
from the
master
cylinder and turn on the brake system warning
light on the instrument panel in the event of a front or
rear system malfunction. The valve and switch are so
designed that the switch
will latch in the "warning"
position once a malfunction has occurred. The only
way the light can be turned off is to repair the
malfunction and
apply a pedal force required to
develop line pressure. The combination valve/P & B
valve is not repairable and must be replaced as a
complete assembly.
P&B valve
(Antilock brake system model only)
Master cylinder (Primary)
Combination valve (Rear wheel antilock model only)
Pressure differential warning switch
Master
cylinder (Secondary)
..(> ..(> Master cylinder (Secondary) Master
cylinder
(Primary)
..(> ..(>
Front brake
Rear brake
Combination Valve
Electrical Circuit Test (RWAL
model
Fig. 5A-4
only)
1.
2.
3.
Disconnect the wmng connector at the
combination
valve (Fig. 5A-5).
• Connect a jumper wire from the harness to
ground.
Turn the ignition key to
"ON".
•
The warning light should come on.
• If the light will not come on, check the bulb. If
the bulb is good, refer to Chassis Electrical
(Sec.
8) for further diagnosis.
Turn the ignition off.
• Disconnect jumper wire and connect the
harness to the switch
terminal.
Combination Valve (RWAL model only)
Warning
Switch Test
1. Raise the vehicle.
• Support
with suitable safety stands.
2. Attach a hose to a rear brake bleeder screw.
• Immerse the opposite end of the hose into a
container
partially filled with clean brake fluid.
3.
4.
5.
6.
7.
¢ Front RH brake
Front LH brake
Rear brake
• Make sure the master cylinder reservoir is full.
Turn the ignition key to "ON".
• Open
the bleeder screw while a helper applies
moderate pressure to the brake pedal.
•
The warning light should come on.
• Close the bleeder screw before the helper
releases
the brake pedal.
Reapply the brake pedal with moderate to heavy
pressure.
• The light should go out.
Attach a hose
to a front brake bleeder screw.
• Immerse the opposite end of the hose into a
container
partially filled with clean brake fluid.
• Make sure the master cylinder reservoir is full.
Turn the ignition key to "ON".
• Open
the bleeder screw while a helper applies
moderate pressure to the brake pedal.
•
The warning light should come on.
• Close the bleeder screw before the helper
releases
the brake pedal.
Reapply
the brake pedal with moderate to heavy
pressure.
• The light should go out.

5A-1 0 HYDRAULIC BRAKES
8. Turn the ignition key off.
• If the warning light does not come on during
steps 3 and
6, but does light when a jumper is
connected to ground, the warning switch
portion
of the valve is faulty. Do not
disassemble any portion of the valve. It must
be replaced.
9. Remove the safety stands.
• Lower the vehicle.
• Check and fill the master cylinder to the proper
level.
VALVE REPLACEMENT
Removal steps 1. Hydraulic pipes
2. Warning switch
connector (Combination valve only)
3. Bolt
4. Combination valve/P&B valve
Installation
steps
To install, follow the removal steps in the reverse order.
Fig. 5A-5
1••1 REMOVAL
• The combination valve/P & 8 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.
1. Hydraulic pipes
• Plug the pipes to prevent the loss of fluid or the
entrance
of dirt.
2. Warning switch connector (Combination valve
only)
3. Bolt
4. Combination valve/P & B valve
1••1 INSTALLATION
4.
3. Combination valve/P & B valve
Bolt
I~I_T_o_r_qu_e_N_·_m_(lb_·_in_) ___,_ ___ 1_3_(_1_13_) __ _
2. Warning switch connector (Combination valve
only)
1. Hydraulic pipes
~~~ Torque N·m (lb·ft) 16 (12)
After installing the brake pipes, bleed brakes as
described in this section.
•

REAR WHEEL ANTILOCK BRAKE SYSTEM 5A3-1
SECTION 5A3
REAR WHEEL ANTILOCK BRAKE SYSTEM
(RWAL}
w CAUTION:
• All brake attaching fasteners are an important attaching part in that they could affect performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part
number or with an equivalent part if replacement becomes necessary. Do not use replacement parts of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of these parts.
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5A3· 1
General Description . .
. . . . . . . . . . . . . . .
5A3· 1
Rear
Wheel Antilock (RWAL) Control
Parts Location . .

. . . . . . . . . . . . . . . . .
5A3· 5
System Diagram . .

. . . . . . . . . . . . . . . . . . . .
5A3· 6
Rear
Wheel Antilock (RWAL) System
Diagnostics . .

. . . . . . . . . . . . . . . . . . . . . .
5A3· 7
On-Vehicle Service . .

. . . . . . . . . . . . . . . . .
5A3·38
RWAL Electronic Brake Control
Module (EBCM) Replacement ....... 5A3-38
Antilock
(Isolation/Dump) Valve
Replacement ..................... 5A3-39
Speed Sensor Replacement
.......... 5A3-40
Main Data and Specifications ........... 5A3-41
Torque Specifications
............... 5A3-41
INTRODUCTION
This section deals with the complete diagnosis and
services
for vehicles equipped with rear wheel
antilock.
For service information regarding all other
components
of the brake system, refer to "Hydraulic
Brakes"
(Sec. SA), "Brake Booster System" (Sec. SA 1)
or "Disc Brakes" (Sec. SA2) of this Manual.
GENERAL DESCRIPTION
The rear wheel anti lock system (RWAL) is designed to
reduce rear wheel lock-up during a severe brake
application,
thus maintaining rear end stability. The
system functions
by regulating the rear hydraulic
brake line pressure. The pressure regulation is
accomplished
by an anti lock valve which is located on
the
front right side of engine room. The anti lock valve
is made up of two valves, a dump valve which releases
pressure into an accumulator and an isolation valve
which maintains rear brake pressure. The valve is
controlled
by a microcomputer which is part of the
Electronic Brake Control Module (EBCM). The
EBCM is mounted at the
front of the center
console. Under severe brake application, as pressure
is
applied to the brake pedal, the EBCM is designed to
permit the valve to do one of three functions or a
combination
of all three. The EBCM will allow the valve
to either maintain the same amount of hydraulic
pressure, release hydraulic pressure through the
dump valve into the accumulator or increase the
pressure by
pulsing the isolation valve.
The EBCM operates by receiving signals from the
speed sensor (which
is located in the differential
carrier), combination
valve and the brake light switch.
The RWAL system is connected
to the RWAL indicator
light located on the dash. An indication of the RWAL
operation and a
bulb check is performed each time the
ignition is turned
"ON". The indicator light will remain
on
for about two seconds. A RWAL system
malfunction is indicated if the RWAL indicator light
stays on, or comes on during driving. To determine the
specific
trouble, refer to "RWAL System Diagnostics"
in this section.