hood release ISUZU TROOPER 1995 Workshop Manual

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

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

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
•

3F4-14 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
..

HYDRAULIC BRAKES 5A-5
ON-VEHICLE SERVICE
FILLING MASTER CYLINDER
RESERVOIR
'\fl CAUTION:
'VI • Use only specified brake fluid. Do not use any
fluid which contains a petroleum base. Do not
use a container which has been used for
petroleum based fluids or a container which is
wet with water. Petroleum based fluids will
cause swelling and distortion of rubber parts in
the
hydraulic brake system. Water mixed with
brake fluid lowers the fluid boiling point. Keep
all fluid containers capped to prevent contami­
nation.
• Always fill the master cylinder reservoir when
the engine is
cold.
•
Never allow the brake fluid to come in contact
with the painted surfaces.
The master
cylinder reservoir must be kept properly
filled
to ensure adequate reserve and to prevent air
and moisture
from entering the hydraulic system.
However, because
of expansion due to heat absorbed
from the brakes and the engine, the reservoir must not
be overfilled. The brake fluid reservoir is on the master
cylinder, which is located under the hood on the
left
side of the cowl. Thoroughly clean reservoir cap
before
removal to avoid getting dirt into reservoir.
Remove cap and diaphragm.
Add fluid as required to
bring level to the "MAX" mark on the reservoir tank.
Use
"DOT 3" Hydraulic Brake Fluid. If the fluid cap
diaphragm is stretched, return
it to the original position
before
installing.
DETERIORATION OF BRAKE FLUID
Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling
point of brake fluid. It may, in turn, result in vapor lock
or deteriorated rubber parts of the hydraulic system.
Be sure to change brake fluid at specified intervals.
If rubber parts are deteriorated, remove all the system
parts and
clean them with alcohol. Prior to reassembly,
dry the cleaned parts with air to remove the alcohol.
Replace all
hoses and rubber parts of the system.
LEAKAGE OF BRAKE FLUID
With engine idling, set shift lever in the neutral position
and continue to depress brake
pedal at a constant
pressure.
Should the pedal stroke become deeper gradually,
leak from the hydraulic pressure system is possible.
Make sure
by visual check that there is no leak.
BLEEDING BRAKE HYDRAULIC SYSTEM
A bleeding operation is necessary to remove air from
the hydraulic brake system whenever air is introduced
into the hydraulic system.
It may be necessary to bleed
the hydraulic system at all four brakes if air has been
introduced through a
low fluid level or by dis­
connecting brake pipes at the master cylinder. If a
brake pipe is disconnected at one
wheel, only that
wheel cylinder/caliper needs to be bled. If pipes are
disconnected at any fitting
located between master
cylinder and brakes, then the brake system served by
the disconnected pipe must
be bled.
1. For 4-wheel Antilock Brake System (ABS)
equipped
vehicle, be sure to remove the ABS
main fuse
40A located at the relay and fuse box
before
bleeding air. If you attempt to bleed air
without removing the main fuse, air cannot be let
out thoroughly, and this may cause damage to the
hydraulic unit.
After bleeding air, be sure to
replace the ABS main fuse back to its original
position.
2. Set the parking brake completely, then start the
engine.
NOTE:
The vacuum booster will be damaged if the
bleeding operation is performed with the engine
off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation.
5. Always use new brake fluid for replenishment.
6. In replenishing brake fluid, take care that air
bubbles do not enter the brake fluid.
•
When the master cylinder is replaced or
overhauled, first bleed the air from the master
cylinder, then from each
wheel cylinder and
caliper following the procedures described
below.
Bleeding the master cylinder (Fig. 5A-1}
7. Disconnect the rear wheel brake pipe master
cylinder (Fig. 5A-1 ). Check the fluid level
and replenish as necessary. If replenished, leave
the system for at least one minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder where the pipe was disconnected with
your finger, then release the brake pedal slowly.
10. Release your finger from the delivery port when
the brake
pedal returns completely.
11. Repeat steps 7 through 9 until the brake fluid
comes out of the delivery port during step 7.

DRIVEABILITY AND EMISSIONS 6E2-55
CHART A-7
(Page 3 of 3)
FUEL SYSTEM PRESSURE TEST
Tools Required: J34730-1 FUEL PRESSURE GAUGE
CAUTION: TO REDUCE THE RISK OF FIRE AND PERSONAL INJURY:
• IT
IS NECESSARY TO RELIEVE FUEL SYSTEM PRESSURE BEFORE CONNECTING A FUEL
PRESSURE GAUGE.
• A SMALL AMOUNT OF FUEL MAY BE RELEASED WHEN DISCONNECTING THE FUEL LINES.
COVER FUEL l-INE FITTINGS WITH A SHOP TOWEL BEFORE DISCONNECTING, TO CATCH ANY
FUEL THATMAYLEAKOUT. PLACETOWELINAPPROVEDCONTAINERWHENDISCONNECTIS
COMPLETED.
FUEL PRESSURE
RELIEF PROCEDURE
1. REMOVE FUEL CAP.
2. REMOVE FUEL PUMP RELAY FROM UNDERHOOD RELAY CENTER.
3. START
ENGINE AND ALLOW TO STALL.
4. CRANK ENGINE FOR ADDITIONAL 30 SECONDS.
5. REMOVE NEGATIVE BATTERY CABLE.
FUEL GAUGE ADAPTER
INSTALLATION
1. REMOVE SHOULDER FITTING CAP.
2. INSTALL FUEL GAUGE J34730-1 TO FUEL RAIL
3. REINSTALL FUEL PUMP RELAY.
4. CONNECT NEGATIVE BATTERY CABLE.
5. IF YOU ARE WORKING ON A DOHC, IT WILL BE NECESSARY TO INSTALL THE INTAKE MANIFOLD RUN
PLATE.
REFER TO SECTION C2 FUEL METERING SYSTEM FOR INTAKE REMOVAL.
REFER TO INTAKE MANIFOLD DIAGNOSTIC PLATE FOR INSTALLATION INSTRUCTIONS, AS WILL AS
CHART A-8 OF THIS SECTION.

6E2-122 DRIVEABILITV AND EMISSIONS
INDUCTION AIR CONTROL PLATE
SYSTEM
Refer to CHART C-2D to diagnose the Induction air
control plate system.
ON-VEHICLE SERVICE
FUEL PUMP RELAY
The fuel pump relay is mounted in the engine
compartment.
Other than checking for loose
connectors, the only service possible is replacement.
MUL TIPORT FUEL INJECTION
COMPONENTS
WCAUTION:
VI • To reduce the risk of fire and personal injury, it
is necessary to relieve the fuel system pressure
before servicing
fuel system components.
• After relieving system pressure, a small
amount of fuel may be released when servicing
fuel lines or connections. In order to reduce the
chance
of personal injury, cover fuel line
fittings with a shop towel before disconnecting,
to catch any
fuel that may leak out. Place the
towel in an approved container when
disconnect is completed.
Fuel Pressure Relief Procedure
1. Remove fuel cap.
2. Remove fuel pump relay from underhood relay
box.
3. Start engine and allow to stall.
4. Crank engine for additional 30 seconds.
5. Remove negative battery cable.
FUEL RAIL ASSEMBL V
An eight digit identification number is stamped on the
side
ofthe fuel rail (Fig. 6E2-75). Refer to this number if
servicing or part replacement is required.
Names
of component parts appear in the numbered
list on the disassembled view (Fig. 6E2-75).
'fCAUTION:
• Do not attempt to remove the fuel inlet fitting
on the
fuel rail, it is staked in place. To do so will
result
in damage to the fuel rail or to the internal
0-ring seal.
•
Do care in removing the fuel rail assembly, to
prevent damage to the injector
electrical
connector terminals and the injector spray tips.
• Prevent dirt and other contaminants from
entering open lines and passages. Fittings
should be capped, and holes plugged, during
servicing.
Before
removal, the fuel rail assembly may be
cleaned with a spray type engine cleaner,
following
package instructions. Do not
immerse fuel rails in liquid cleaning solvent.
Fig. 6E2-75
I'
---------------------'
•

8-270 CHASSIS ELECTRICAL
ANTI-THEFT SYSTEM
GENERAL DESCRIPTION .......
The circuit consists ofthe starter switch, anti-theft controller, anti-theft horn, front door and tailgate key switch
(detect and tamper switch),
door lock (&power window) switch, door lock actuator for each door, engine hood
switch, clutch start switch (MfT),
ANTI-THEFT indicator light and mode switch (AfT). The system operates as
follows: After locking the starter switch and removing the starter key (this sets the alarm),
ifthe door is unlocked
in any
way other than with the proper key, the headlights start flashing, the horn sounds, and the starter circuit
is disabled. (However,
the engine hood and all the doors must be locked and closed.)
Once the system has been placed in the warning or alarm condition, it can be released only when the starter
switch is shifted
from "OFF" to "ACC" by the starter key, or when the lock of the front door or the tailgate is
released (to activate the detect switch)
by the starter key.
OPERATION OF ANTI-THEFT SYSTEM
'
'
CLUTCH START m
SW(M/Tiw
' '
'
BATIERY(+)
0 ST
STARTER sw
BATIERY(+)
L------
STARTER RELAY
' ' (MIT):
'
'
'
HORN
(SOUND)
ANTI-THEFT CONTROLLER
BATIERY(+)
LIGHTING
RELAY
"ON"
HEAD­LIGHT (FLASH)
NOTE: Arrow marks u ~ u indicate the direction of current
Fig. 8-314
•

8-276 CHASSIS ELECTRICAL
Item Malfunction
Possible cause
Detecting method Remarks
Alarm
does not
Defective contact of tailgate switch When luggage room light switch
G operate even or defective wiring. is turned on with tailgate open, with tailgate
luggage room light does not open
come on.
Even when
Defective contact
of tailgate detect Check controller connector. Refer to "Connector tailgate is open-
switch, or damaged wiring.
check procedure" in H ed with key, this system.
alarm does not
stop.
Even when en-
Damaged engine hood switch or gine hood is wiring.
opened with
I remote release,
alarm does not
operate
Even when
Defective contact
of starter switch. With starter switch turned to
J starter switch is II ACC" position, audio, cigarette
turned, alarm
lighter and door mirrors (on
does not stop
II ACC" circuit) do not operate.
Damaged
door switch, or a short After closing door, dome light
circuit in wiring. and courtesy light remain on.
K Indicator light
continues Damaged tamper switch, or a
Check controller connector. Refer to "Connector flashing
short circuit in wiring. check
procedure" in
this system.
..

------------- -
CHASSIS ELECTRICAL 8-279
Step Operation Item to be checked Item of Remarks
malfunction
34 Close right rear door.
Insert key into key cylinder of right
Check to see if indicator light stays 35 front door and turn it in lock on steadily. B direction.
36 Wait about 10 seconds. Check
to see if indicator light goes c Activate alarm device. off after about 10 seconds.
37 Unlock right front door with lock-Check to see if alarm operates. D Only right front door ing knob.
is unlocked.
Insert
key into key cylinder of right With
key at unlock
position, check to see 38 front door and turn it in unlock Check to see if alarm stops E if alarm stops. (With
direction.
all doors unlocked.)
Check to see if indicator light flashes.
39 Open right front door.
A
Check to
see if dome light and
courtesy light come on.
40 Close right front door.
Check to
see if indicator light stays 41 Lock right front door with key.
on steadily. B
42 Wait about 10 seconds. Check
to see if indicator light goes c Activate alarm device. off after about 10 seconds.
43 Unlock right front door with key. Check
to see if alarm does not F operate.
Check to
see if indicator light stays 44 Lock right front door with key.
on steadily. B
45 Wait about 10 seconds. Check
to see if indicator light goes c Activate alarm device. off after about 10 seconds.
46 Open engine hood with engine
Check to see if alarm operates. I hood release handle.
47 Insert key into starter switch and
Check to see if alarm stops. J turn it to "ACC" position.
NOTE: When the connector of the anti-theft controller is disconnected, the starter is inoperative.
In the checking of short wheel base model, Step Nos. 16 through 21 and Step Nos. 31 through 36
are omitted.