torque ISUZU TROOPER 1995 Workshop Manual

9J-126 Supplemental Restraint System
INSTALLATION
1. Install the steering wheel and align the setting ~
marks.
2. Tighten the steering fixing nut to the specified
torque.
Torque : 34N·m(25 lb·ft.).
3. Connect horn lead connector.
4. Connect inflator module to 2-way yellow wiring
harness connector.
5. Install inflator module into steering wheel and
torque fasteners.
Torque: 8N·m(69 lb·in.)
6. Enable the SRS (Refer to "Enabling the SRS" in
this section.).
•

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.).
•

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

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.
..

10-32 BODY
DOORS
FRONT DOOR ASSEMBLY
4. Front door assembly
Fig. 10-23
1++1 REMOVAL
Preparation: Disconnect the battery ground cable
1. Door check arm pin (Fig. 10-24)
Fig.
10-24
2. Hinge bolt
• Align the hinge bolt to the door side hinge
and
put a maker on it.
3. Door harness connection
• Pull the door harness grommet out and
disconnect the harness connection (Fig.
10-
25). Fig.
10-25
4. Front
door assembly
I++IINSTALLATION
To install, follow the removal steps in the reverse
order,
noting the following points.
1. Align the door fitting to the body by referring
to "BODY DIMENSIONS" in this section.
2. Tighten the door hinge bolts to the specified
torque.
~~~ Torque N·m (lb·ftl I 34 (25)
3. Apply chassis grease to the door check arm pin
and
door hinge moving surface.
REAR DOOR ASSEMBLY
Fig. 10-26
1++1 REMOVAL
Preparation: Disconnect the battery ground cable ~
Apply an setting mark on the body
side hinge.
•

1. Door check arm pin (Fig. 10-27)
2. Hinge bolt
• Open the front door and remove the body
side hinge bolts. (Fig. 10-28)
3. Door harness connection
• Pull the door harness grommet out and
disconnect
the door harness connection.
(Fig. 1
0-29)
4. Door assembly
Door check arm pin
Fig. 10-27
Setting mark
Center pillar
Fig. 10-28
LJ

Center pillar
Rear door
~
Fig. 10-29
BODY 1o:-33
I++IINSTALLATION
To install, follow the removal steps in the reverse
order,
noting the following points.
1. Align the door fitting to the body by referring
to "BODY DIMENSIONS" in this section.
2. Tighten the door hinge bolts to the specified
torque.
1~1 Torque N·m (lb.ft) 34 (25)
3. Apply chassis grease to the check arm pin and
door hinge moving surface.
DOOR STRIKERS
I~EI ADJUSTMENT (fig. 10-30)
Door striker
Fig. 10-30
1. Loosen striker screws.
2. Tap with plastic hammer to align.
3. Tighten the striker screws.
~~~ Torque N·m {lb·ft) 15 (11)

1o-34 BODY
DOOR CHECK ARM ASSEMBLY (FRONT & REAR)
Front (or center) pillar
Front (or Rear) door
2
Fixing location Mark
FRT DOOR RH 960 R F
FRT DOOR LH 960 L F
RR
DOOR RH 960 R R Removal steps
RR DOOR LH 960 L R 1. Door trim panel
3
2. Check arm pin 3. Check arm assembly
Installation steps
To
install, follow the removal
steps in
the reverse order.
Fig. 10-31
1++1 REMOVAL
Preparation:
Disconnect the battery ground cable
1. Door trim panel
• Refer to "DOOR TRIM PANEL" removal
procedure in this section.
2. Check
arm pin (Fig. 10-24)
3. Check arm assembly
• Carefully peel off the water proof sheet as
much as necessary, for check arm removal.
I••IINSTALLATION
To install, follow the removal steps in the reverse
order,
noting the following point.
1. When installing the check arm assembly, note
its marking
to ensure using the appropriate
part. (Fig.
10-31)
2. Tighten the check arm fixing nuts to the
specified torque.
~~~ Torque N-m (lb·in) I 13(113)
3. Apply chassis grease to the check arm pin
moving surface.
..

10-42 BODY
Fig. 10-52
Fig. 10-53
5. Window regulator (Fig. 10-54)
6.
7.
• Disconnect the window regulator motor
harness connector (W/Power window).
Window regulator fix
Rear guide rail fix
Fig. 10-54
Glass
run
• Pull the glass run out from the door frame
groove. (Fig. 10-55)
Rear
guide rail
Fig. 10-55
E) INSTALLATION
To install, follow the removal steps in the reverse
order,
noting the following points.
1. Apply soap and water to the door frame
groove and insert the glass run to the door
frame from the @ corner in the arrow-marked
directions. (Fig.
10-50)
2.
3.
Install the glass run with its wider end pointed
to the inside of the vehicle. (Fig. 10-56)
Glass run
Inside Outside
Fig. 10-56
Set the glass
into the door panel with the front
side of the glass lowered and insert the rear
side
of the glass into the glass run. Then insert
the
front side of the glass into the glass run to
install the glass to the glass run while raising it
up along the glass run.
Tighten the
window regulator and glass fixing
bolts and nuts to the specified torque.
~~~ _T_o_r~q_u_e ____ N_·m __ (l_b_·i_n) __ ~ ___ 8_(_6_9_) ____ _
4. Check to see if the window regulator operates
smoothly and the glass opens and closes
properly.
Install the waterproof sheet with no
clearance between the door panel and the
waterproof sheet.
•