sensor ISUZU TROOPER 1998 Service Repair Manual

4D1±20
TRANSFER CASE (STANDARD TYPE)
Removal
1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and
driven gear.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove the front companion flange and the rear
companion flange, using the flange companion holder
5±8840±0133±0 (J±8614±11) to remove the end
nuts.
262RW067
NOTE: U s e a u n i v e r s a l p u l l e r t o remove the rear
companion flange.
5. Disconnect the transfer breather hose from the
control box.
6. Remove the control box assembly.
7. Remove the transfer rear cover assembly from the
transfer case assembly.
Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.
220RS017
2. Install the transfer rear cover assembly to the transfer
case assembly.
3. Perform the following steps before fitting the transfer
rear case:
1. Shift the high±low shift rod to the 4H side.
2. Turn the select rod counterclockwise so that the
select block projection may enter into the
2WD±4WD shift block.
3. The cut±away portion of the select rod head (9)
should align with that of the rear case hole's
stopper (10).
230RW004
4. Tighten the transfer rear case bolts to the specified
torque.
Torque: 37 N´m (3.8kg´m/27 lb ft)

4D1±22
TRANSFER CASE (STANDARD TYPE)
15. Install the speedometer sensor and tighten to the
specified torque.
Torque: 27 N´m (2.8kg´m/20 lb ft)
225RW014

4D2±3 TRANSFER CASE (TOD)
6. Disconnect the wiring harness connector and shift
lock cable and then remove the front console.
7. Remove the selector lever assembly and put it aside.
8. Remove the transfer control lever.
9. Disconnect the breather hose.
10. Remove the left front exhaust pipe fixing bolts and
nuts, and put the exhaust pipe aside.
11. Remove the left seat belt tension rod and put the rear
proper shaft aside.
260RW006
12. Remove the silencer.
13. Disconnect the transfer connector from the top of the
transfer case.
14. Disconnect the speed sensor harness connector.
15. Remove the fuel pipe clip fixing bolt on the transfer
case.
16. Support the transmission with a jack.
17. Remove the seven bolts from the transfer case.
18. Remove transfer case assembly.
Installation
To install, follow the removal steps in the reverse order,
nothing the following points:
1. Apply a thin coat of grease (Besco L2) or equivalent to
the input shaft spline.
261RW024
2. Mount the transfer case.

4D2±8
TRANSFER CASE (TOD)
Unit Repair
Inspection
Before disassembling and after assembling, check the
following items on the transfer connector terminals.
No.
NAMECONTENTS
1Ref . (Ref . )Rear speed sensor refer-
ence output
2Ref . (Frt . )Front speed sensor refer-
ence output
3SW GNDSW GND
44H SW (+)4H SW plus terminal
5Rer . (+)Rear speed sensor plus
6Frt . (+)Front speed sensor plus
7POWER GNDPower GND
8SOL (+)Electromagnetic solenoid
9COM (±) (Ref .)Rear speed sensor GND
10COM (±) (Frt .)Front speed sensor GND
11NC
124L SW (+)4L SW plus terminal
810RW002
4H and 4L switches
Check whether the 4H switch (terminals 4 and 7) and 4L
switch (terminals 12 and 3 ) work as specified in the table
below. If yes, the continuity is established on these
switches. If not, check the switches, shift rails, transfer
case, and rear cover, and replace the failed parts.
SHIFT POSI-
TION
PIN 4 (4 to 7)PIN 12 (3 to 12)
HIGHOFFOFF
(NEUTRAL)ONON
4LOFFON
Power GND
Check that there is a continuity between the power GND
pin (terminal 7) and transfer case. If not, replace the
grounding wire.
Resistance of electromagnetic coil
Check the resistance between electromagnetic clutch
solenoid (terminal 8) and power GND (terminal 7). If not,
replace the electromagnetic coil.
Standard : 1.4 ~ 2.0

Allowable : 1.0 ~ 5.0

4D2±12
TRANSFER CASE (TOD)
Transfer Cover Assembly
Disassembled View
261RW007
Legend
(1) Coil Assembly
(2) Snap Ring
(3) Ball Bearing(4) Speed Gear and Tone Wheel
(5) Ball Bearing
(6) Transfer Cover Assembly
(7) Front and Rear Speed Sensors
Disassembly
1. Using snap ring pliers, remove the snap ring.
261RW047

4D2±14
TRANSFER CASE (TOD)
6. Using the bearing remover 5-8840-2409-0 (J-42805)
and slide hammer 5-8840-0084-0 (J-2619-01),
remove the ball bearing for the front output shaft.
901RW234
7. Remove the bolts and front and rear speed sensors.
NOTE: Be careful not to damage the speed sensors
during the work.
261RW033
Reassembly
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (Besco L2 or equivalent).
3. Using the oil seal installer 5-8840-2412-0 (J-42804),
install the oil seal to the transfer cover assembly.
261RW051
Rear Output Shaft Oil Seal
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Dimension : 9.85 Ð 10.35mm (0.39 Ð 0.41 in)
A04RW004

4D2±15 TRANSFER CASE (TOD)
4. Apply a thin coat of grease to the seal ring of each
front and rear speed sensor, and mount the sensors
carefully.
5. Tighten the bolts to the specified torque.
Torque : 5 N´m (0.5 kg´m/43 lb in)
NOTE: Pay attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.
6. Install the ball bearing (1) for the front output shaft as
flat as shown in the figure.
261RW008
7. Mount the coil assembly and tighten the nuts to the
specified torque.
Torque : 10 N´m (1.0 kg´m/87 lb in)
8. Connect the terminal in the central connector.
NOTE: Be careful not to damage other terminals.
9. Install speed gear and tone wheel.
10. Mount the ball bearing (2) as flat as shown in the
figure.
261RW009±1
11. Using snap ring pliers, install the snap ring to the
transfer cover assembly.NOTE: Securely install the snap ring to the groove of the
transfer cover assembly.

5A±1 BRAKE CONTROL SYSTEM
BRAKES
CONTENTS
Brake Control System 5A. . . . . . . . . . . . . . . . . . . .
Anti±lock Brake System 5B. . . . . . . . . . . . . . . . . . Power±Assisted Brake System 5C. . . . . . . . . . . .
Parking Brakes 5D. . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CONTROL SYSTEM
CONTENTS
Service Precaution 5A±2. . . . . . . . . . . . . . . . . . . . . .
General Description 5A±3. . . . . . . . . . . . . . . . . . . . .
System Components 5A±3. . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit (EHCU) 5A±3.
ABS Warning Light 5A±4. . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor 5A±4. . . . . . . . . . . . . . . . . .
G-Sensor 5A±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal and Anti-lock Braking 5A±4. . . . . . . . . . .
Brake Pedal Travel 5A±4. . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations 5A±4. . . . . . . . . . . .
General Diagnosis 5A±5. . . . . . . . . . . . . . . . . . . . . . .
General Information 5A±5. . . . . . . . . . . . . . . . . . . .
ABS Service Precautions 5A±5. . . . . . . . . . . . . . .
Computer System Service Precautions 5A±5. . .
General Service Precautions 5A±5. . . . . . . . . . . .
Note on Intermittents 5A±5. . . . . . . . . . . . . . . . . . .
Test Driving ABS Complaint Vehicles 5A±6. . . . .
ªABSº Warning Light 5A±6. . . . . . . . . . . . . . . . . . .
Normal Operation 5A±6. . . . . . . . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 5A±6. . . . . . . . . . . .
Basic Inspection Procedure 5A±7. . . . . . . . . . . . .
Tech 2 Scan Tool 5A±8. . . . . . . . . . . . . . . . . . . . . .
Getting Started 5A±9. . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure 5A±10. . . . . . . . . . . . . . . . . . .
Data List 5A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EHCU Connector Pin-out Checks 5A±12. . . . . . . .
Circuit Diagram (LHD model / 6VD1 and
4JG2) 5A±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram (LHD model / 4JG2) 5A±14. . . . .
Circuit Diagram (LHD model / 4JG2) 5A±15. . . . .
Circuit Diagram (LHD model / 6VD1) 5A±16. . . . .
Circuit Diagram (LHD model / 6VD1) 5A±17. . . . .
Connector List (LHD model) 5A±18. . . . . . . . . . . .
Part Location (LHD model) 5A±20. . . . . . . . . . . . . .
Circuit Diagram (RHD model / 6VD1 and
4JG2) 5A±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram (RHD model / 4JG2) 5A±22. . . . .
Circuit Diagram (RHD model / 4JG2) 5A±23. . . . .
Circuit Diagram (RHD model / 6VD1) 5A±24. . . . .
Circuit Diagram (RHD model / 6VD1) 5A±25. . . . .
Circuit Diagram (RHD model / 6VE1 and
4JX1) 5A±26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram (RHD model / 4JX1) 5A±27. . . . .
Circuit Diagram (RHD model / 4JX1) 5A±28. . . . .
Circuit Diagram (RHD model / 6VE1) 5A±29. . . . .
Circuit Diagram (RHD model / 6VE1) 5A±30. . . . .
Connector List (RHD model) 5A±31. . . . . . . . . . . .
Part Location (RHD model) 5A±34. . . . . . . . . . . . .
Symptom Diagnosis 5A±35. . . . . . . . . . . . . . . . . . . . .
Chart A±1 ABS Works Frequently But
Vehicle Does Not Decelerate 5A±35. . . . . . . . . . .
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate (Use
TECH 2) 5A±36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart A-2 Uneven Braking Occurs While
ABS Works 5A±36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart A-3, TA-3 The Wheels Are Locked 5A±36.
Chart A-4 Brake Pedal Feed Is Abnormal 5A±37.
Chart A-5, TA-5 Braking Sound (From
EHCU) Is Heard While Not Braking 5A±38. . . . . .
Diagnostic Trouble Codes 5A±39. . . . . . . . . . . . . . . .
Diagnosis By ªABSº Warning Light
Illumination Pattern 5A±40. . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) 5A±40. . . . . . .
Chart B-1 With the key in the ON position
(Before starting the engine). Warning light
(W/L) is not activated. 5A±43. . . . . . . . . . . . . . . . .
Chart B-2 EHCU Abnormality (DTC 14) 5A±43. . .
Chart B-3 Power Voltage Drop (DTC 15) 5A±44. .
Chart B-4 CLASS-2 Communication Line
Abnormality (DTC 16) 5A±44. . . . . . . . . . . . . . . . .
Chart B-5 G-Sensor Circuit (DTC 21) 5A±45. . . . .
Chart B-6 Abnormal Transmission Input
(DTC 23) 5A±46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-7 Transfer Monitor (DTC 24) 5A±47. . . . .
Chart B-8 EHCU Pump Motor And Motor
Relay Circuit (DTC 32) 5A±47. . . . . . . . . . . . . . . . .
Chart B-9 EHCU Pump Valve And Valve
Relay Circuit (DTC 35) 5A±47. . . . . . . . . . . . . . . . .
Chart B-10 FL Isolation Solenoid Valve
Abnormality (DTC 41) 5A±48. . . . . . . . . . . . . . . . .
Chart B-11 FL Dump Solenoid Valve
Abnormality (DTC 42) 5A±48. . . . . . . . . . . . . . . . .
Chart B-12 FR Isolation Solenoid Valve
Abnormality (DTC 43) 5A±48. . . . . . . . . . . . . . . . .
Chart B-13 FR Dump Solenoid Valve
Abnormality (DTC 44) 5A±49. . . . . . . . . . . . . . . . .
Chart B-14 Rear Isolation Solenoid Valve
Abnormality (DTC 45) 5A±49. . . . . . . . . . . . . . . . .
Chart B-15 Rear Dump Solenoid Valve
Abnormality (DTC 46) 5A±49. . . . . . . . . . . . . . . . .

5A±2
BRAKE CONTROL SYSTEM
Chart B-16 FL Speed Sensor Disconnection
(DTC 51) 5A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-17 FR Speed Sensor Disconnection
(DTC 52) 5A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-18 RL Speed Sensor Disconnection
(DTC 53) 5A±51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-19 RR Speed Sensor Disconnection
(DTC 54) 5A±51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-20 FL Speed Sensor Short Circuit
(DTC 61) 5A±52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-21 FR Speed Sensor Short Circuit
(DTC 62) 5A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-22 RL Speed Sensor Short Circuit
(DTC 63) 5A±54. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-23 RR Speed Sensor Short Circuit
(DTC 64) 5A±55. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-24 Sensor Signal Input Abnormality
(DTC 65) 5A±56. . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Signal Abnormality Criteria using
TECH 2 5A±56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Inspection Procedure 5A±57. . . . . . . . . . . . . . . .
Chart C-1-1 FL Sensor Output Inspection
Procedure 5A±57. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-2 FR Sensor Output Inspection
Procedure 5A±58. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-3 RL Sensor Output Inspection
Procedure 5A±58. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-4 RR Sensor Output Inspection
Procedure 5A±59. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TC-1 Sensor Output Inspection
Procedure (Use TECH 2) 5A±59. . . . . . . . . . . . . .
Chart C-2 Transmission Input Inspection
Procedure 5A±60. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TC-2 Transmission Input Inspection
Procedure (Use TECH 2) 5A±61. . . . . . . . . . . . . .
Special Tools 5A±62. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

5A±3 BRAKE CONTROL SYSTEM
General Description
The Anti-lock Brake System (ABS) works on all four
wheels. A combination of wheel speed sensor and
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking.This system helps the driver maintain greater control of
the vehicle under heavy braking conditions.
C05RW027
Legend
(1) With P&B Valve Model
(2) With LSPV Model
(3) Electronic Hydraulic Control Unit (EHCU)
(4) Front Wheel Speed Sensor
(5) Rear Wheel Speed Sensor(6) G-Sensor
(7) Proportioning and Bypass (P&B) Valve
(8) Load Sensing Proportioning Valve (LSPV)
(9) Electronic Line
(10) Hydraulic Line
System Components
Electronic Hydraulic Control Unit (EHCU), four Wheel
Speed Sensors, Warning Light, and G-sensor.
Electronic Hydraulic Control Unit (EHCU)
The EHCU consists of ABS control circuits, fault detector,
and a fail-safe. It drives the hydraulic unit according to the
signal from each sensor, cancelling ABS to return to