door lock ISUZU TROOPER 1995 Workshop Manual

IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER (VIN)
This is the legal identification of the vehicle. It is
located
on the left bottom of the windshield. It can
be easily seen
through the windshield from outside
the vehicle (Fig.
OA-1).
~ !~ :i ~ v * ~7L_
~Sequential Number
Assembly Plant
Model Year (5 = 1995)
Check Digit
GENERAL INFORMATION OA-5
Fig. OA-1
Engine Type (V = 3.2L V6 SOHC ; 6VD1)
(W = 3.2L V6
DOHC ; 6VD1)
Body Type
(7 = 2 Door Cab ; Short Wheel Base)
(8 = 4 Door Cab ; Long Wheel Base)
Series
Vehicle Line
(J =with SRS-Air Bag model)
GVWR Range
(0 = 5001 -6000 LBS)
World Manufacturer Identifier
ENGINE SERIAL NUMBER
The gasoline engine serial number is stamped on
the
left rear lower area of the cylinder block above
the starter (Fig. OA-2).
Fig. OA-2

MAINTENANCE AND LUBRICATION OB-1
SECTION 08
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule List . . . . . . . . . . . . 08-1
Explanation of Complete Vehicle
Mai-ntenance Schedule . . . . . . . . . . . . . . 08-4
Recommended
Fluids and Lubricants . . . . 08-8
Lubricant Viscosity Chart ............... 08-9
Recommended Liquid Gasket
........... 08-11
Recommended Thread Locking Agents ... 08-11
Maintenance Service Data .............. 08-12
MAINTENANCE SCHEDULE LIST
NORMAL VEHICLE USE
The maintenance instructions in this Maintenance
Schedule are based on the assumption that the vehicle
will
be used as designed:
• to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of
the glove compartment door;
• to be driven on reasonable road surfaces within
legal operating limits;
•
to be driven on a daily basis, as a general rule, for at
least several miles/kilometers;
•
to be driven on unleaded fuel
Unusual
or severe operating conditions will require
more frequent car maintenance,
as specified in the
following sections.
ITEMS
CHANGE ENGINE OIL AND OIL FIL TEA
CHANGE AUTOMATIC TRANSMISSION FLUID
SEVERE DRIVING CONDITIONS
If the vehicle is usually operated under any of the
severe driving conditions
listed below, it is
recommended that the
applicable maintenance
services be performed at the specified
interval shown
in the chart
below.
Severe driving conditions
• Repeated short trips in cold weather
• Driving in dusty areas
• Frequent idling and/or frequent low-speed
operation
• Towing a trailer
INTERVAL
Every 4,800 km (3,000 miles) or 3 months
Every
32,000 km (20,000 miles)

FLUID LEVEL CHECK
A fluid loss in any system (except windshield
washer) may indicate a problem. Repair the system
at once.
Engine
oil level -Check level and add if
necessary. The best time to check the engine oil
level is
when the oil is warm. After stopping the
engine with the vehicle on a level surface, wait a
few minutes for the oil to drain back to the oil pan.
Pull
out the oil level indicator (dipstick). Wipe it
clean and push the oil level indicator back down all
the
way. Pull out the oil level indicator, keeping the
tip down, and look at the oil level on it.
Add oil, if needed, to keep the oil level above
the
"ADD" mark and between the "ADD" and
"FULL" marks in the operating range area. Avoid
overfilling the engine since this may cause engine
damage. Push
the oil level indicator back down all
the
way after taking the reading.
If you check the oil level when the oil is cold, do
not run the engine first. The cold oil will not drain
back
to the pan fast enough to give a true oil level.
Engine coolant level and condition -Check
engine coolant level in the coolant reservoir and
add engine
coolant if necessary. Inspect the engine
coolant and replace it if dirty or rusty.
Windshield washer fluid level -Check washer
fluid level in reservoir and add if necessary.
Power steering system reservoir level-Check
and keep at
proper level.
Brake master cylinder reservoir level -Check
fluid. Keep fluid at proper level. A low fluid level
can indicate
worn disc brake pads which may need
to be serviced.
Hydraulic clutch system -Check fluid l~vel in
the reservoir.
Add fluid as required.
Battery fluid level -Check fluid level in the
battery.
FLUID LEAK CHECK
Check for fuel, water, oil or other fluid leaks by
looking at the surface beneath the vehicle after it
has been parked for a while. Water dripping from
the air conditioning system after use is normal. If
you notice gasoline fumes or fluid at any time,
locate the source and correct it at once.
ENGINE OIL AND OIL FILTER
REPLACEMENT
Always use API SE, SF, SG, SH or ILSAC GF-1
quality oils of the proper viscosity.
When choosing an oil, consider the range of
temperatures the car will be operated in before the
next oil change. Then, select the recommended oil
viscosity
from the chart (Fig. OB-1).
Always change the oil and the oil filter as soon as
possible after driving in a dust storm.
MAINTENANCE AND LUBRICATION OB-5
ENGINE COOLING SYSTEM INSPECTION
Inspect coolant/anti-freeze. If coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep
coolant at the proper mixture for proper freeze
protection,
corrosion inhibitor level and best engine
operating temperature.
Inspect hoses and replace if
cracked, swollen or deteriorated. Tighten hose
clamps if equipped with screw-type clamps. Clean
outside of radiator and air conditioning condenser.
Wash
filler cap and neck. To help ensure proper
operation, a pressure test of both the cooling
system and cap is also recommended.
EXHAUST SYSTEM INSPECTION
Visually inspect the exhaust pipes, muffler, heat
shields and hangers
for cracks, deterioration, or
damage.
Be alert to any changes in the sound of the exhaust
system
or any smell of fumes. These are signs the
system may be leaking or overheating. Repair the
system at once,
if these conditions exist. (See also
"Engine Exhaust Gas Safety" and "Three Way
Catalytic Converter" in Owner's manual.)
FUEL CAP, FUEL LINES, AND FUEL TANK
INSPECTION
Inspect the fuel tank, the fuel cap and the fuel lines
every
60,000 miles (96,000 km) for damage which
could cause leakage.
Inspect the fuel cap and the gasket for correct sealing
and physical damage. Replace any damaged parts.
DRIVE BELT INSPECTION
Check the belts driving the steering oil pump, the air
conditioning compressor, and the generator
for
cracks, fraying, wear, and correct tension every 30,000
miles (48,000 km). Adjust or replace as necessary.
WHEEL ALIGNMENT, BALANCE AND
TIRES OPERATION
Uneven or abnormal tire wear, or a pull right or left
on a straight and level road may show the need for
a wheel alignment. A vibration of the steering
wheel or seat at normal highway speeds means a
wheel balancing is needed. Check tire pressure
when the tires are "cold" (include the spare).
Maintain pressure as shown in the tire placard,
which is located on the driver's door lock pillar.
STEERING SYSTEM OPERATION
Be alert for any changes in steering action. An
inspection
or service is needed when the steering
wheel is harder
to turn or has too much free play, or
if there are unusual sounds when turning or parking.

OB-6 MAINTENANCE AND LUBRICATION
BRAKE SYSTEMS OPERATION
Watch for the "BRAKE" light coming on. Other
signs of possible brake trouble are such things as
repeated pulling to one side when braking, unusual
sounds
when braking or between brake
applications,
or increased brake pedal travel. If you
note one of these conditions, repair the system at
once.
For convenience, the
following should be done
when wheels are removed for rotation: Inspect lines
and hoses
for proper hookup, bindings, leaks, crack,
chafing etc.
Inspect disc brake pads for wear and
rotors
for surface condition.
Inspect other brake parts, including parking brake
drums, linings etc., at the same time. Check parking
brake adjustment.
Inspect brakes more often if habit or
conditions
result in frequent braking.
PARKING BRAKE AND TRANSMISSION
PARK MECHANISM OPERATION
Park on a fairly steep hill and hold the vehicle with
the parking brake only. This checks holding ability.
On
automatic transmission vehicles, shifting from
"P" position to the other positions cannot be made
unless
the brake pedal is depressed when the key
switch is in
"ON" position or the engine running.
WARNING
•
Before checking starter safety switch
operation below,
be sure to have enough
room around the
vehicle. Then firmly apply
both the parking brake and the regular brake.
Do not
use the accelerator pedal. If the engine
starts, be ready
to turn off the key promptly.
Take these precautions because the vehicle
could move
without warning and possibly
cause personal injury
or property damage.
STARTER SAFETY SWITCH OPERATION
(AUTOMATIC TRANSMISSION)
Check by trying to start the engine in each gear
while setting the parking brake and the foot brake.
The starter
should crank only in "P" (Park) or "N"
(Neutral).
STARTER SAFETY SWITCH OPERATION
(MANUAL TRANSMISSION)
To check, place the shift lever in "Neutral", push
the clutch pedal halfway and try to start. The starter
should not crank. The starter should crank only
when the clutch pedal is fully depressed.
ACCELERATOR LINKAGE LUBRICATION
Lubricate the accelerator pedal fulcrum pin with
chassis grease.
STEERING AND SUSPENSION
INSPECTION
Inspect front and rear suspension and steering
system
for damaged, loose or missing parts or signs
of wear. Inspect power steering lines and hoses for
proper hookup, binding, leaks, cracks, chafing, etc.
BODY AND CHASSIS LUBRICATION
Lubricate the key lock cylinders, the hood latch, the
hood and door hinges, the door check link, the
parking cable guides,
the underbody contact points,
and the linkage.
PROPELLER SHAFT INSPECTION AND
LUBRICATION
Lubricate sliding yoke and universal joints with
grease containing MOS2 (disulfide molybdenum
type grease) at the interval shown in the
Maintenance Schedule. Check for play in normal
direction of rotation of sliding yoke and universal
joints. Also check
propeller shaft flange-to-pinion
bolts for proper torque of 63 N·m (46 lb·ft) for front
and rear propeller shaft.
AUTOMATIC TRANSMISSION FLUID
INSPECTION
Check the lubricant level every 7,500 miles (12,000
km) and add lubricant
if necessary.
Under harsh operating conditions, such as constant
driving in heavy city traffic during
hot weather, or in
hilly or mountainous terrain, change the transmission
fluid and service the
sump filter after every 20,000
miles (32,000 km) of operation.
AUTO CRUISE CONTROL INSPECTION
Check to see if the clearance between cruise link and
accelerator is normal. Also check that the vacuum
hoses are routed and connected properly.
CLUTCH LINES AND HOSES INSPECTION
Check lines and hoses for proper attachment,
binding, leaks, cracks, chafing, deterioration, etc.
Any questionable parts should be replaced or
repaired at once. When abrasion or wear is evident
on lines or hoses, the cause must be corrected.
..

OB-8 MAINTENANCE AND LUBRICATION
RECOMMENDED FLUIDS AND LUBRICANTS
USAGE FLUID/LUBRICANT
Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil
(See oil
chart on the following page for
proper viscosity)
Engine
coolant Mixture of water and good quality ethylene glycol
base type antifreeze.
Brake system
DOT-3 hydraulic brake fluid.
Power steering system
DEXRON® 11-E Automatic transmission fluid.
Automatic transmission DEXRON®-III Automatic transmission fluid.
Manual transmission
Engine oil
(See oil
chart on following page for proper viscosity)
Rear
axle and front axle GL-5 gear lubricant (Standard differential)
GL-5 Limited slip differential gear lubricant (If
equipped with optional limited slip differential)
(See oil
chart in this section for proper viscosity)
Clutch system
a. Pivot points Engine oil
b. Clutch fork joint Chassis grease
c. Master cylinder DOT-3 hydraulic brake fluid
Hood latch assembly
a. Pivots and spring anchor
Engine oil
b. Release pawl Chassis grease
Hood and
door hinges
Engine oil
Chassis lubrication Chassis greae
Parking brake
cables Chassis grease
Front wheel bearings Wheel bearing grease
Free
Wheeling hubs (Automatic) Specified grease (available as service parts)
Propeller shafts
Sliding yoke and Universal joint Grease containing MoS2 or multipurpose type
grease NLGI No.2
Body
door hinge pins and linkage, fuel door hinge,
Engine oil
rear compartment lid hinges
Windshield washer solvent Washer fluid
Key lock cylinder Engine oil
Accelerator linkage
Chassis grease

1A-4 HEATING AND VENTILATION
AIR SELECT KNOB
The air select knob allows you to direct heated air
into the passenger
compartment through different
outlets (Fig. 1A-4).
1. Vent -In this position, air is discharged from
the upper air
outlet. Air quantity is controlled
by the fan control knob.
2. Bi-Level -In this position, air flow is divided
between the upper air
outlets and the floor air
outlets, with warmer air delivered to the floor
outlets
than the air delivered to the upper air
outlets.
3. Foot -In this position, air flow is delivered to
the foot only.
4. Def/Foot -In this position, air flow is delivered
to the foot, while sending approx. 30% of total
amount of air to the windshield.
5. Defrost -In this position, most of the air is
delivered to the windshield and a small amount
is delivered to the side windows.
Moving the air source select lever to the "CIRC"
position provides quickest heat delivery by closing
the blower assembly mode door. In this position,
outside air
is not delivered to the passenger
compartment.
Heater unit
D
Heater core TO FOOT
AIR SOURCE SELECT LEVER
The intake of outside air and the circulation of
inside air are controlled by sliding this lever left or
right.
FAN CONTROL KNOB
This knob controls the blower motor speed to
regulate the amount of air delivered to the defrost,
foot, and
ventilation ducts:
1. Low
2. Medium Low
3. Medium High
4. High
TEMPERATURE CONTROL KNOB
When the temperature control knob is in the
"COLD" position, the air mix door closes to block
the flow of air to the heater core.
When the temperature
control knob is in the "HOT"
position, the air mix door opens to allow air to pass
through the heater core and heat the passenger
compartment.
Placing the knob in an intermediate position will
cause a lesser or greater amount of air to reach the
heater core.
In this mode the passenger compart­
ment temperature can be regulated.
.r.( /
<_;~~
'--'R!I=---_____.J'
TO FOOT OUTLET
VENT MODE 81-LEVEL MODE FOOT MODE
TO FOOT OUTLET
DEF/FOOT MODE DEF MODE
Fig. 1A-4
<==:J : COLD AIR
~: HOTAIR
~ : TEMP.CONTROLLED AIR
I ........................................................................\
...... ------------------~1

INFLATION OF TIRES
Tire pressure, in cold condition (after vehicle has setfor
three hours or more, and driven less than one mile),
should
be checked monthly or before any extended
trip. Tire pressure increases
approximately 15% when
the tires become hot during driving. Tire pressure
specification is shown on the
label located on the left
door lock pillar (Fig. 3E-5).
Fig.
3E-5
NOTE:
Check the tire pressure whenever irregular wear is
found. Tire
inflation greatly affects tire wear. If the
alignment check does not reveal any alignment
problems,
check the condition of the shock absorbers
and
wheel/tire balance.
WHEELS AND TIRES 3E-3
DIAGNOSIS LIST
If the following conditions are noted, rotation is
required.
1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left and right front tire wear is unequal.
4. Left and right rear tire wear is unequal.
If
the following conditions are noted, check the wheel
alignment.
1. Left and right front tire wear is unequal.
2. Uneven wear exists across the tread of any tire.
3. Front tire treads have scuffed appearance with
"feather" edges on one side of tread ribs or
blocks.
4. There is cupping, flat spotting etc.
Higher than recommended pressure can cause:
1. Hard ride.
2. Poor steering stability.
3. Rapid and uneven wear at center of the tread.
Lower than recommended pressure can cause:
1. Tire squeal on turns.
2. Hard steering.
3. Rapid and uneven wear on the edges of the tread.
4. Tire rim bruises and rupture.
5. Tire cord breakage.
6. High tire temperatures.
7. Reduced handling.
8. Reduced fuel economy.
Unequal pressure on same axle can cause:
1. Uneven braking
2. Steering lead.
3. Reduced handling.
4. Swerve on acceleration

CHASSIS ELECTRICAL 8-1
·SECTION 8
CHASSIS ELECTRICAL
'\f 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 that are not reused, and those requiring thread
locking compound, will be called out. The correct
torque
values must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
CONTENTS
General Information .................................... 8-2
Notes for Working on Electrical
Items .................................................... 8-2
Symbols and Abbreviations ................. 8-8
Symbols ............................................ 8-8
Abbreviations ................................... 8-9
Parts for Electrical Circuit ..................... 8-10
Wiring ............................................... 8-10
Fuse .................................................. 8-11
Fusible Link ....................................... 8-12
Circuit Breaker ................................... 8-12
Relay ................................................. 8-12
Relay Specifications and
Configurations ................................ 8-13
Diode ................................................. 8-14
Connector ......................................... 8-15
Reading the Circuit Diagram ................ 8-17
Main Data and Specifications .................... 8-19
Bulb Specifications ................................ 8-19
Fuse,
Fusible Link and
Circuit Breaker Location ..................... 8-21
Fuse
Block Circuit .................................. 8-22
Reference Table of Fuse, Fusible
Link and Circuit Breaker ..................... 8-23
Relay Location ....................................... 8-27
Diode Location .......................................
8-28
Grounding Point .................................... 8-29
Reference Table ................................ 8-29
Location ............................................ 8-31
Cable Harness Routing .......................... 8-34
System Repair .............................................. 8-38
Start and Charging ................................ 8-38
Engine Control Module
(ECM) ................................................... 8-47
Headlight and Fog Light ........................ 8-58
Front Side Marker Light, Parking Light,
Taillight, License Plate Light and
Illumination Light .............................. 8-76
Stoplight and Rear Defogger .............. 8-92
Turn Signal Light, Hazard
Warning
Light, Cornering Light,
Backup
Light and Horn ..................... 8-106
Dome Light, Luggage room Light,
Courtesy Light, Map Light,
Seat Belt Switch and
Warning Buzzer ................................. 8-128
Power Door Lock ................................. 8-142
Power
Window .................................... 8-156
Cruise
Control ...................................... 8-172
Anti-Lock Brake
System (ABS) ........... 8-178
Rear
Wheel Anti-Lock Brake
System (RWAL) ................................. 8-185
Transmission
Control Module
(TCM) ................................................. 8-192
A/T Shift Lock ...................................... 8-200
Windshield
Wiper/Washer and
Rear
Wiper/Washer .......................... 8-205
Headlight wiper /washer ..................... 8-232
Audio, Auto Antenna,
Cigarette
Lighter and digital clock ... 8-246
Power Door Mirror ............................... 8-254
Anti-theft System ................................ 8-270
Meter and Warning/Indicator Light ... 8-288
A/T Shift Indicator ............................... 8-336
Heater and
Air Conditioning ............... 8-340
Sun
Roof ............................................... 8-346
Power Seat ........................................... 8-360
Seat
Heater .......................................... 8-37 4
Supplemental Restraint
System (SRS) -AIR BAG ................... 8-382

-·*; ~---
8-2 CHASSIS ELECTRICAL
GENERAL INFORMATION
The chassis electrical system is of 12-volt specifications with a negative ground polarity.
Wire sizes are appropriate
to respective circuits, and classified by color. (The classification of harnesses by
color is shown on the circuit diagram for ease of harness identification.)
The
wire size is determined by load capacity and the length of wire required.
The
vehicle harnesses are: body harness, chassis harness, engine room harness, instrument harness,
transmission harness, engine
ECGI harness, dome light harness, door harness, rear body harness, tailgate
harness,
SRS harness and battery cables.
The harnesses are protected either
by tape or corrugated tube, depending on harness location.
The circuit
for each system consists of the power source, wire, fuse, relay, switch, load parts and ground, all of
which are shown on the circuit diagram.
In this manual, each electrical device is classified by system. For major parts shown on the circuit based on
the circuit diagram
for each system, a summary, diagnosis oftroubles, inspection and removal and installation
procedures are detailed.
NOTES FOR WORKING ON ELECTRICAL ITEMS
Disconnecting the Battery Cable (Fig. 8-1)
Ground cable
Fig. 8-1
1. All switches should be in the "OFF" position.
2. Disconnect the battery ground cable.
3. Disconnect the battery positive cable.
W CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can
result in a short circuit.
Connecting the Battery Cable
Follow the disconnecting procedure in the reverse
order.
\V CAUTION:
Clean the battery terminal and apply a light coat
of grease to prevent terminal corrosion.
Connector Handling
Disconnecting The Connectors (Fig. 8-2)
Fig. 8-2
Some connectors have a tang lock to hold the connec­
tors together during vehicle operation.
Some tang locks are released by pulling them towards
you
G).
Other tang locks are released by pressing them for­
ward®.
Determine which type oftang lock is on the connector
being handled.
Firmly grasp both sides (male and female)
of the
connector. Release the tang lock and carefully pull the
two halves
of the connector apart.
Never pull on the wires
to separate the connectors.
This
will result in wire breakage (Fig. 8-3).
.,
..

CHASSIS ELECTRICAL 8-21
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER LOCATION
ooooo 112~12~1~1~1
00 E
EEr 00 ~
Relay & fuse box
SJOOO 7-6
I lw ;;::;~ Fuse box ~ ~
1l1~~ ~lff~UIH~Inll
w~ F-a FL-4 ~
00 FL·S~ r---, F-11 'l2~J1~ 1~1&11~11~1,\l~31hl1~1
0
0
FL-6 'F-i2
I' ~
\a~ a~;
0000
0000
I ~
l/
~
j
~/~/ e:;?' v II I / / .I / /
('-/ .
~~
-~-~;,a~ ~~ --.:_
~~~~ -
Relay & Fuse box Fuse box
Fuse
Fuse Fuse
No. Capacity Indication on label No. Capacity Indication on label No. Capacity Indication on label
F-1 --C-1 10A STARTER RELAY
C-14 15A STOP A!f CONT
F-2 10A 02 SENSOR HEATER C-2 15A (SEAT HEATER)
C-15 20A (AUDIO [8))
F-3
15A HORN HAZARD C-3 15A
TURN BACK C-16 10A CLOCK (8] ROOM
F-4
15A H/LAMP-LH C-4 10A ELEC.IGN. C-17 25A RR DEFOG
F-5
15A H/LAMP-RH C-5
15A FRTWIPER & C-18 20A (DOOR LOCK)
F-6 --WASHER C-19
25A BLOWER
F-7
- -C-6 10A RRWIPER & C-20 10A (AIR
CON)
F-8
15A (FRT.FOG) WASHER C-21 10A SRS-1
F-9 20A ABS C-7 10A (H/LAMP C-22 10A SRS-2
F-10
15A FUEL PUMP WIPER) C-23 lOA SRS-3
F-11 -
-C-8 15A ENGINE C-24 10A SRS-4
F-12
15A TAIL C-9 15A IGN. COIL CIRCUIT BREAKER
FUSIBLE
LINK
C-10 10A METER GAUGE
C/8-1 --FL-1 80A MAIN C-11 10A
(AUDIO IACC])
C/8-2 30A (P/W, P/S, S/R)
FL-2 50 A KEYSW MIRROR
FL-3 30A ECM C-12 20A CIGARETTE 02: Oxygen
FL-6 40A (ASS 4/WHEEL ONLY) C-13 10A (ANTI THEFT)
Fig. 8-44