ISUZU TROOPER 1995 Workshop Manual

PARKING BRAKES 5C-1
SECTION 5C
PARKING BRAKES
'\f7 CAUTION:
Yf 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 ofthe same
part number
or with and 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
General Description ..................... 5C-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2
On-Vehicle Service
..................... 5C-3
Parking Brake Lever Replacement . .

. . . . .
5C-3
Parking Brake Front Cable . .

. . . . . . . . . . .
5C-4
Parking Brake Rear Cable . .

. . . . . . . . . . . .
5C-5
Parking Brake Lining Inspection ......... 5C-6
Parking Brake Rotor (Drum) Inspection ... 5C-6
Parking Brake Adjustment .............. 5C-7
Main Data and Specifications ............. 5C-8
General
Specifications ................. 5C-8
Torque Specifications ................. 5C-8
GENERAL DESCRIPTION
Pulling up the parking brake lever by hand will set the
parking brake.
Once pulled up, the lever is held by a
ratchet type
lock until it is released. The position of the
lever is transmitted through cable/lever systems to the
rear
wheels. These parts are designed to obtain
sufficient braking force
when parking on slopes. When
the parking brake is set,
or when the ignition SW is in
the
"ON" position, the brake warning light illuminates.
The rear wheel parking brake is a duo-servo brake
(mechanical inside expansion type) built in to the rear
disc brake. Parking brake adjustment is made through
the adjusting
hole (bored through back plate). Parking
brake
lever stroke should be adjusted to 6 or 7
notches. Refer
to "Parking Brake Adjustment" in
this Section.

5C-2 PARKING BRAKES
OPERATION (Fig. SC-1)
When pulled in the direction "A", the parking lever
presses the secondary shoe against the brake drum
using the lever/shoe joint "8" as a fulcrum and pushes
the strut in the direction
"C". The strut, in turn, presses
the primary shoe against the brake drum.
Counter
force "D" to the primary shoe is transmitted again to
Primary shoe
Parking cable guide
the secondary shoe through the fulcrum "8". The
secondary shoe contacts the
drum thereby producing
braking effect.
Clearance which may result from worn
parking brake shoe lining can be adjusted by turning
the adjusting screw. Refer to
"Parking Brake
Adjustment"
in this Section.
Fulcrum B
Adjusting hole plug
Adjusting screw notch
Fig. 5C-1
•

~
PARKING BRAKES SC-3
ON-VEHICLE SERVICE
PARKING BRAKE LEVER REPLACEMENT
1
4
6
Removal steps
1. Center console
2. Switch
connector 3. Bolt
4. Pin and snap pin
5. Parking brake
front cable 6. Parking brake lever
Installation
steps
To install, follow the removal
steps in the reverse order.
Fig. 5C-2
l••l REMOVAL
1.
2.
3.
4.
5.
Center console
• Refer to Section 1 0 "Body".
Switch connector
Bolt
Pin and snap pin
Parking brake front
cable
• Loosen the parking brake front cable at the
floor connector.
• Disconnect the parking brake front cable from
the parking brake lever (Fig. 5C-2).
6. Parking brake lever
1••1 INSTALLATION
6. Parking brake lever
5. Parking brake front cable
4. Pin and snap pin
r:::J • Apply grease (BESCO L-2 or equivalent) to the
D pin before installing.
3. Bolt
• Tighten the parking brake lever fixing bolt to
the specified torque.
~~~ Torque N·m (lb·in) 13 (113)
2. Switch connector
1. Center console
• Refer to Section 10 "Body".
•
To adjust the parking brake lever, see "Parking
Brake Adjustment" in this Section.

5C-4 PARKING BRAKES
PARKING BRAKE FRONT CABLE
<.~ '"''"' brnke '""" ~
~~~ ~ ~
o®~ 6. Front cable ~ 2. Adjust nut
··"""-v>.?
~
~
#
~WBmodel
,----~
~~
~ ~--___j 1. Center console
Fig. 5C-3
1••1 REMOVAL
1. Center console
• Refer to Section 10 "Body".
2. Adjust nut
• Loosen the adjust nut of the rear cables.
3. Rear cables
• Remove the rear cables from the brackets and
disconnect the cables
from the front cable.
4. Bolt
5. Parking brake lever
• Disconnect the front cable from the lever joint.
(Refer to
"Parking Brake Lever Replacement"
on the previous page.)
6. Front cable
1•+1 INSTALLATION
6. Front cable
5.
4.
Parking brake lever
Bolt
I~I_T_o_rq_u_e ___ N_·_m_(lb_·_in_) --'---6_(_5_2) __
3. Rear cables
r;:::;:] • Apply grease (BESCO L-2 or equivalent) to the
D connecting portion of the rear cable and
equalizer.
2. Adjust nut
• Tighten the adjust nut to the specified torque.
~~~ Torque N-m (lb-in) J 6 (52)
• To adjust the parking brake, refer to "Parking
Brake
Adjustment" in this Section.
1 . Center console
•

PARKING BRAKE REAR CABLE
1
v9
;#
~SWBmodel
Fig. 5C-4
E) REMOVAL
1. Rear wheels
2. Caliper assembly
• Remove 2 bolts to remove the caliper assembly
from the support bracket. (Refer to "Rear Disc
Brakes" in
Section 5A2). Temporarily hang the
caliper with wire to avoid stretching the brake
hose.
3. Rotor (Drum)
4.
Holding spring
5. Return spring; upper
6. Return spring; lower
7. Shoe assembly
• Remove the brake shoe assembly. Then
remove the parking brake
cable from the
parking brake
lever. (Fig. 5C-5) 8.
9.
10.
11.
12.
13.
14. 15.
Cable fixing bolt
Clip
Clip
Clip
Adjust nut
Back
plate
Equalizer
Rear cable
PARKING BRAKES SC-5
Removal steps
1. Rear wheels
2. Caliper assembly 3. Rotor (Drum)
4. Holding spring 5. Return spring; upper
6. Return spring; lower 7. Shoe assembly 8. Cable fixing bolt 9. Clip 10.Ciip 11. Clip
12. Adjust nut 13. Back plate 14. Equalizer 15. Rear cable
Installation
steps To install, follow the removal steps in the reverse order.
Parking brake lever
Fig. SC-5

5C-6 PARKING BRAKES
1••1 INSTALLATION
15. Rear cable
hl • Apply grease (BESCO L-2 or equivalent) to the
D connecting portion of the rear cable and
equalizer.
14. Equalizer
13. Back plate
12. Adjust nut
• Tighten the adjust nut to the specified torque.
1~1 Torque N-m (lb-in) I 6 (52)
• To adjust the parking brake, refer to "Parking
Brake Adjustment" in this Section.
11,10, 9. Clip
~~~ Torque N·m (lb·in) I 6 (52)
8. Cable fixing bolt
• Tighten the cable fixing bolt to the specified
torque.
~~~ Torque N·m (lb·in) 6 (52)
7. Shoe assembly
h1 • After installation of the shoe and cable
D assembly, apply special grease (included in the
repair kit)
to the following portions indicated in
the figure (Fig.
5C-6)
Fig. 5C-6
6. Return spring; lower
5. Return spring; upper
• The parking brake lever side (secondary side)
return spring
must be installed on the outer
side
of the primary side return spring (Fig. 5C-
7).
+Outer side
Fig. 5C-7
4. Holding spring
3. Rotor (Drum)
2. Caliper assembly
1. Rear wheels
Parking lever
PARKING BRAKE LINING INSPECTION
(Fig. SC-8)
Check the shoe assemblies for wear by removing the
brake
drum rotor.
Replace the shoe assemblies, if the lining thickness is
less than 1.0 mm (0.039 in).
1@1 Minimum limit mm (in) J 1.0 (0.039)
-1---r-----------------------,_1_ . '
T I It
u
Fig. 5C-8
PARKING BRAKE ROTOR (DRUM)
INSPECTION
Refer to "Rear Disc Brakes" in Section 5A2 for
inspection procedure
of the rotor (drum).
•

PARKING BRAKE ADJUSTMENT
1. Adjustment of parking brake assembly
• Prior to lever stroke adjustment, adjust the rear
brake
shoe/rotor (drum) gap. Perform this
procedure
by loosening the adjust nut of the
equalizer.
a) Remove the adjusting hole plug (rubber) and
turn the shoe adjusting screw
downward with a
small screwdriver so that shoes will expand
until
they get into close touch with the rotor.
(Turn
down the adjusting screw notch by notch
until the rotor does not turn.)
b) Turn the adjusting screw in the opposite
direction (upward) until the rotor can
be turned
lightly. Standard
number of notches to turn
upward: 7 or 8.
Turn the rotor and make sure that there is no
brake dragging.
2. Adjustment of parking brake cable
a) Turn the equalizer nut so that the parking brake
lever travels 6
or 7 notches when pulled up with
a force of 30 kg (66 lb).
b) Make sure there is no brake dragging and
tighten the cable lock nut.
l~l Torque N·m (lb·in) 6 (52)
3. Break-in of parking brake shoe
• When poor braking effect possibly resulting
from insufficient break-in is felt, or just after
replacement
of parking brake shoe, be sure to
conduct break-in by driving vehicle as follows:
a) Forward 50 km/h (30 mph) x 400 m (About 30
seconds) with a lever pull force of 15 kg (33 lb),
and
b) Backward 10 km/h (6 mph) x 50 m (18 sec-
onds)
with a lever pull force of 15 kg (33 lb).
NOTE:
Break-in procedure must be performed under the
safety conditions and traffic rules.
• If braking effect still remains poor after the
above break-in,
wait for some time until
parking brake shoe cools
down and repeat the
procedures
a) and b) noted above.
• On completion of break-in, inspect parking
brake lever stroke, and
if the lever does not
come within the specified number of notches
when pulled up, readjust.
• Excessive brake-in may cause premature wear
of the parking brake lining.
PARKING BRAKES SC-7

SC-8 PARKING BRAKES
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Rear parking brake
Type Lining dimension
Adjusting method
Rotor (drum) inside diameter
Parking brake
lever stroke
mm (in) Duo-servo
121.2
(18.79)
Manual adjusting
210 (8.27)
6 to 7 notches
When pulled
with a force of 30 kg (66 lb)
TORQUE SPECIFICATIONS N·m (lb·in}
Fig. 5C-9
•

ENGINE DIAGNOSIS S-1
ENGINE
CONTENTS
Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section S
General
Engine Mechanical .................................................... Section SA
3.2L VS Engine ............................................................... Section SA1
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section S8
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SC
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SD
Driveability and Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SE2
Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SF
SECTION 6
ENGINE GENERAL INFORMATION
CONTENTS
Description of Engine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
DESCRIPTION OF ENGINE SECTION
SECTIONS-ENGINE GENERAL INFORMATION SECTION S8-ENGINE COOLING
General description
Engine cleanliness and care, and general information
on engine service are covered in this section.
Engine diagnosis
This section covers the components of the fuel,
ignition, and mechanical systems that could cause a
particular complaint, and then outlines repairs in a
logical sequence.
SECTION SA-ENGINE MECHANICAL
This section contains information on the mechanical
parts of the engine, such as cylinder block, cylinder
head, crankshaft, pistons, valve train, camshaft, and
engine
lubrication.
Overhaul
procedures, removal and replacement
procedures, and specifications are also covered.
Specific subsections are:
SA-GENERAL;
Disassembly and reassembly procedures,
inspection and repair procedures
off the vehicle.
6A 1-3.2L V6 ENGINE;
Removal
and replacement procedures on the
vehicle.
Engine cooling system components such as radiator,
engine
coolant pump, thermostat, and cooling fan, are
covered
in this section.
SECTION SC-ENGINE FUEL
This section contains information on all the parts of the
fuel system except the fuel injectors, or throttle body II
unit itself. Items covered are: fuel tank, fuel pump, fuel
filter,
and fuel lines. Specific sections are used for each
fuel system type:
Port
Injection fuel rail and injectors will be found in
Section
6E2.
SECTION SD-ENGINE ELECTRICAL
Items covered in this section are battery, generator,
starter, ignition
coil, spark plugs and wires.
Ignition system diagnosis will be found in Section 6E2
as a "C4" chart.
Specific sections are:
601 -Battery
602 - Cranking System
603 -Charging System
604 -Ignition System

6-2 ENGINE DIAGNOSIS
SECTION 6E-DRIVEABILITY
AND EMISSIONS
This section covers emission control systems general
information, and diagnostic procedures which will lead
to repairing performance and driveability related
problems.
Emission components are covered, as well
as removal and replacement procedures.
Instructions on use
of special tools are also given.
SECTION 6F-ENGINE EXHAUST
This section has information on all exhaust system
parts, such
as tailpipes, mufflers, and the catalytic
converter.
GENERAL DESCRIPTION
ENGINE CLEANLINESS AND CARE
An automobile engine is a combination of many
machined, honed,
polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any
internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and
protection
of machined surfaces and friction areas is
part
of the repair procedure. This is considered
standard shop practice even
if not specifically stated.
• A liberal coating of engine oil should be applied to
all friction areas during assembly to protect and
lubricate the surfaces on initial operation.
• Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and
crankshaft
journal bearings are removed for
service, they should be retained in order.
• At the time of installation, they should be installed
in the same locations and with the same mating
surfaces
as when removed.
• Battery cables should be disconnected before any
major
work is performed on the engine. Failure to
disconnect
cables may result in damage to wire
harness
or other electrical parts.
• The six cylinders of this engine are identified by
numbers; Right side
cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
GENERAL INFORMATION ON ENGINE
SERVICE
The following information on engine service should be
noted
carefully, as it is important in preventing damage
and contributing
to reliable engine performance.
• When raising or supporting the engine for any
reason,
do not use a jack under the oil pan. Due to
the
small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may
cause damage to the
oil pick-up unit.
• The 12-volt electrical system is capable of
damaging circuits. When performing any work
where electrical terminals could possibly be
grounded, the ground cable of the battery should
be disconnected at the battery.
• Any time the intake air duct or air cleaner is
removed, the intake opening
should be covered.
This
will protect against accidental entrance of
foreign material into the cylinder which could
cause extensive damage when the engine is
started.
ENGINE DIAGNOSIS
CONTENTS
Hard Starting . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Compression
Test Procedure ..... 6-4
Rough Engine
Idling or Engine Stalling . . . 6-5
Rough Engine Running . . . . . . . . . . . . . . . . .
6-6
Hesitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Engine Lacks
Power . . . . . . . . . . . . . . . . . . . . 6-8
Engine
Noisy .......................... 6-10
Abnormal Combustion . . . . . . . . . . . . . . . . . . 6-12
Engine Oil Consumption Excessive . . . . . . . 6-13
Fuel Consumption Excessive ............. 6-14
Oil Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Malfunction Indicator Lamp . . . . . . . . . . . . . . 6-15
Engine Oil Pressure Check ............... 6-16
Inspection of Hydraulic Lash Adjuster . . . . . 6-17