engine ISUZU TROOPER 1998 Service Repair Manual

7C±8CLUTCH
Diagnosis
ConditionPossible causeCorrection
DraggingFluid leakage.Repair
Air in hydraulic line.Bleed
Master cylinder and slave cylinder
seals worn. Replace master cylinder.
Replace slave cylinder seals.
Driven plate warped.Replace driven plate.
Diaphragm spring weakened or tip of
fingers worn. Replace pressure plate
Driven plate sticking on splines.Lubricate with grease or replace.
Clutch spline worn. Repair
Release bearing worn or damaged.Replace release bearing.
SlippingDriven plate facing worn or
oil±soaked.Replace driven plate and check for
leaks.
Diaphragm spring weakened.Replace pressure plate.
Pressure plate or flywheel warped.Correct or replace.
Master cylinder and slave cylinder
seals worn.Replace master cylinder.
Replace slave cylinder seals.
ChatteringEngine mounts loose or damaged.Tighten or replace.
Driven plate facing warped.Replace driven plate.
Surface of facing hardened.Replace driven plate
Driven plate facing oil soaked. Replace driven plate and check for
leaks.
Damper springs weakened or
broken. Replace.
Pressure plate or flywheel warped.Correct or replace.
NoisyReplace bearing binding.Correct, or replace if damaged, and
lubricate.
Replace bearing worn or damaged. Replace release bearing.
Release bearing poorly lubricated. Lubricate.
Pilot bearing worn.Replace pilot bearing.
Damper springs weakened or
broken.Replace driven plate.
Rivets of driven plate exposed.Replace driven plate.
Replace driven plate.Hydraulic line blocked.Clean out or replace.
Master or slave cylinders binding.Repair or replace as needed.

7C±14CLUTCH
Release Bearing
201RS011
1. Visually check the release bearing for excessive play,
noise and breakage.
2. If any of these conditions are discovered, the release
bearing must be replaced.
3. When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.
201RW010
Legend
(1) Wire Ring
(2) Pressure Plate Assembly
(3) Wedge Collar
(4) T/M Side
(5) Release Bearing
(6) Engine Side
Wedge Collar
201RS013
1. Visually check the surfaces of the wedge collar
making contact with the release bearing for excessive
wear and damage.
2. Replace any exhibiting excessive wear or damage.
Shift Fork
201RS014
1. Visually check the surfaces of the shift fork making
contact with the release bearing for excessive wear
and damage.
2. Remove any minor stepping or abrasion from shift
fork with an oil stone.
3. Replace any exhibiting excessive wear or damage.

7C±20CLUTCH
2. Adjust clutch padel adjusting bolt by backing it out
half a turn, and measure the clearance (
)
between the clutch pedal arm and the adjusting
bolt.
203RW010
Legend
(9) Bracket
(10) Clutch Pedal Adjusting Bolt
(11) Lock Nut
(12) Clutch Pedal Arm
3. Lock the lock nut.
Clutch Switch and Clutch Pedal Clearance (
)
0.5 mm ± 1.5 mm (0.020 in ± 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm ± 15 mm (0.20 in ± 0.59 in)
203RW004
6. Clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the
wheels.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:

Hydraulic circuit for fluid leakage or air in circuit.

Clutch disc warped.

Diaphragm spring weakened or tip of fingers worn.

Driven plate sticking on sprines.

Release bearing worn or damaged.

Master cylinder and slave cylinder worn.
203RW007
Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height

LIGHTING SYSTEM8A–29
Light NameRated PowerNumber of
BulbsLens ColorRemarks
Headlight60w/55w2WhiteHalogen
FrontTurn signal light21w2Whitecombination
lightClearance light5w2Amber
FRT fog light55w2WhiteHalogen
Taillight/Stoplight5w/21w2Red
RearBumperTurn signal light21w2Ambercombination
lightTaillight/Stoplight5w/21w2RedBodyTurn signal light21w2Amber
Backup light21w2White
RR fog light21w2Red
Side turn signal light5w2Amber
License plate lightBumper5w2White
Body5W1White
High mount stoplight——RedLED
Map light5w2White
Dome light10w1White
Luggage room light8w1White
Courtesy light3.8w2White
A/C SW60mA1
RR defogger SW0.84w1
Mirror defogger SW0.84w1
FRT fog light SW0.7w1
RR fog light SW0.7w1
Cruise (Set)1.4w1Meter
Cruise (Main)1.4w1Meter
Check trans3w1Meter
Anti-theft3w1Warning box
Turn signal1.4w2Meter
Golw1.4w1Meter
Water sedimenter1.4w1Meter
Indicator/High beam1.4w1MeterWarning
lightABS1.4w1Meter
Check engine1.4w1Meter
Low fuel1.4w1Meter
4WD1.4w1Meter
Oil Pressure1.4w1Meter
Brake system1.4w1Meter
Charge1.4w1Meter
Seat belt2w1Meter
A/T shift position0.91w7Meter
A/T oil temp3w1Meter

8A–30LIGHTING SYSTEM
Power drive1.4w1Meter
Winter drive1.4w1Meter
Air bag2w1Meter
Engine warming SW0.84w1
FRT fog light SW0.84w1
RR fog light SW0.84w1
Glove box1.2w1
Ashtray1.4w1
Illumination controller0.7w1
Heater bezel150mA2
Hazard warning light SW0.84w1
Meter3.4w4Meter ASM
IlluminationCigar lighter1.4w1Light
Rear wiper & washer SW0.84w1
Rear defogger SW0.84w1
Mirror control SW45mA1
Mirror defogger SW0.7w1
Mirror folding SW0.7w1
A/T select lever1.2w1
Power & Winter SW50mA2
Cruise control main SW0.84w1
Headlight wiper SW0.84w1
Torque Specifications
ApplicationN·mkg·mLb FtLb In
Steering Shaft Nut343.525—

8DÐ4 WIRING SYSTEM
The chassis electrical system is a 12Ðvolt system with a
negative ground polarity.
Wire size 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 section, 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 of
troubles and inspection procedures are detailed.
Notes for Working on Electrical
Items
Disconnecting the Battery Cable
1. All switches should be in the ÒOFFÓ position.
2. Disconnect the battery ground cable (2).
3. Disconnect the battery positive cable (1).
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.CAUTION: Clean the battery terminal and apply a
light coat of grease to prevent terminal corrosion.
Disconnecting the Connector
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards
you (1).
Other tang locks are released by pressing them forward
(2).
Determine which type of tang lock is on the connector
being handled.
Firmly grasp both sides (male and female) of the
connector (3).
Release the tang lock and carefully pull the two halves of
the connector apart.
Never pull on the wires to separate the connectors (4).
2
1
General Description
1
2
3
4

8DÐ8 WIRING SYSTEM
5. The wiring harness between engine and chassis
should be long enough (2). Tension of the wire (1) may
causes chafing or damage due to various vibrations.
Splicing Wire
1. If the harness is taped, remove the tape. To avoid wire
insulation damage, use a sewing Òseam ripperÓ
(available from sewing supply stores) to cut open the
harness.
If the harness has a black plastic conduit, simply pull
out the desired wire.
2. Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire later
if you decide to cut more wire off to change the location
of a splice. You may have to adjust splice locations to
make certain that each splice is at least 1Ð1/2Ó
(40 mm) away from other splices, harness branches,
or connectors.
3. When replacing a wire, use a wire of the same size as
the original wire.
Check the stripped wire for nicks or cut stands. If the
wire is damaged, repeat the procedure on a new
section of wire. The two stripped wire ends should be
equal in length.
4. Select the proper clip to secure the splice.
To determine the proper clip size for the wire being
spliced, follow the directions included with your clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them
between your thumb and forefinger as shown in the
figure.
The center the spline clip (1) under the stripped wires
and hold it in place.cOpen the crimping tool to its full width and rest one
handle on a firm flat surface.
cCenter the back of the splice clip on the proper anvil
and close the crimping tool to the point where the back
of the splice clip touches the wings of the clip.
cMake sure that the clip and wires are still in the correct
position. Then, apply steady pressure until the
crimping tool closes as shown in the figure.
2
11

WIRING SYSTEM 8DÐ11
Abbreviation Meaning of Abbreviation
A
ABS
ASM
AC
A/C
ACC
A/T
C/B
CSD
DIS
EBCM
ECGI
ECM
ECU
EFE
EGR
4A/T
4WD
FL
FRT
H/L
IC
IGAmpere (S)
Anti-lock brake system
Assembly
Alternating current
Air conditioner
Accessories
Automatic transmission
Circuit breaker
Cold start device
Direct ignition system
Electronic brake control module
Electronic control gasoline injection
Engine control module
Electronic control unit
Early fuel evaporation
Exhaust gas recirculation
4-speed automatic transmission
Four-wheel drive
Fusible link
Front
Headlight
Integrated circuit
IgnitionAbbreviation Meaning of Abbreviation
kW
LH
LWB
M/T
OD
OPT
PCM
QOS
RH
RR
SDM
SRS
ST
STD
SW
SWB
3A/T
V
VSV
W
WOT
W/
W/OKilowatt
Left hand
Long wheel base
Manual transmission
Over drive
Option
Powertrain control module
Quick on start
Right hand
Rear
Sensing and diagnostic module
Supplemental restraint system
Start
Standard
Switch
Short wheel base
3-speed automatic transmission
Volt
Vacuum switching valve
Watt (S)
Wide open throttle
With
Without
Abbreviations

8DÐ26 WIRING SYSTEM
Fuse Box
This illustration is based on RHD
C/B-1 C/B-2
C-10
C-20C-9 C-8 C-7 C-6 C-5 C-4 C-3 C-2 C-1
C-19 C-18 C-17 C-16 C-15 C-14 C-13 C-12 C-11
C-21 C-22 C-23 C-24
FUSE BOX
RHDNo.
C-1
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11
C-12
C-13
C-14
C-15
C-16
C-17
C-18
C-19
C-20
C-21
C-22
C-23
C-24LHD
10A STARTER RELAY
15A SEAT HEATER
10A TURN, BACK
10A ELEC. IGN.
15A FRT WIPER AND WASHER
10A RR WIPER AND WASHER
10A H/LAMP WIPER
15A ENGINE
15A IGN. COIL (GASOLINE)
15A FUEL CUT (4JG2)
10A METER, GAUGE
10A AUDIO, MIRROR
20A CIGARETTE
10A ANTI-THEFT
15A STOP, A/T CONT.
20A TELEPHONE
10A CLOCK, ROOM
25A RR DEFOG.
20A DOOR LOCK
25A BLOWER
10A AIR CON.
10A SRS-110A STARTER RELAY
15A SEAT HEATER
10A TURN, BACK
10A ELEC. IGN.
15A FRT WIPER AND WASHER
10A RR WIPER AND WASHER
10A H/LAMP WIPER
15A ENGINE
15A IGN. COIL (GASOLINE)
15A FUEL CUT (4JG2)
10A METER, GAUGE
10A AUDIO, MIRROR
20A CIGARETTE
10A ANTI-THEFT
15A STOP, A/T CONT.
20A TELEPHONE
10A CLOCK, ROOM
25A RR DEFOG.
20A DOOR LOCK
25A BLOWER
10A AIR CON.
10A SRS-1 FUSE
RHDNo.
C/B-1
C/B-2LHD
30A P/W, P/S, S/R 30A P/W, P/S, S/R—— CIRCUIT BREAKER
—
—
——
—
—
810RV026

WIRING SYSTEM 8DÐ31
Fuse Block Circuit
RHD Models
Indication on label
BOFF
STIG2 ACC
STARTER SW
+
_
O SENSOR (V6)
HORN, HAZARD
H/LAMP-LH
H/LAMP-RH
(FRT . FOG)
ABS
F/ PUMP (V6)
P/ WINDOW, S/ ROOF,
P/SEAT
STARTER RELAY
TURN, BACK
ELEC. IGN.
FRT WIPER & WASHER
RR WIPER & WASHER
H/ LAMP WIPER
ENGINE
IGN. COIL (G)
FUEL CUT (D)
METER, GAUGE
AUDIO(ACC)
MIRROR
CIGAR
STOP, A/T CONT.
AUDIO(B)
TEL(B)
CLOCK(B)
ROOM
RR DEFOG
DOOR LOCK
IG1B
STARTER
C
B
AC GENERATOR
BL
IG
F-1
F-2 10A
F-3 15A
F-4 15A
F-5 15A
F-8 20A
F-9 20A
F-10 15A
C/B-2 30A
C-1 10A
C-3 10A
C-4 10A
C-5 15A
C-6 10A
C-7 10A
C-8 15A
C-9 15A
C-10 10A
C-11 10A
C-12 20A
C-14 15A
C-15 20A
C-16 10A
C-17 25A
C-18 20A RELAY; STARTERCHARGE SIGNAL
FUSE BOX
RELAY; ECM MAIN
FUEL
INJECTOR ECM
HYDRAULIC
UNIT FL-3
30A ECM
FL-6
40A ABS
FL-2
50A KEY SW FL-1
80A MAIN2
2
1
5 W
5 W
8 B/R 5 W
F-6
F-7
F-11
RELAY & FUSE BOX
C-2 15A
BLOWERC-19 25A
C-20 10A
5 W 5 W
5 W
1.25 R
5 W
5 W
3 W
2 R
3 W
3 B/R
3 W
3 W/G
3 B/Y 3 B/Y
5 W 5 W
3 B/W
3 W/B
3 W/B 3 W/B3 W/G 2 W
30 B/R
0.85 B/Y
3 L/B
3 W
1.25 R/G
SFL-2
(DIESEL)
SEAT HEATER
FL-3
40A C/HEATER
FL-5
50A GLOW
CERAMIC HEATER
(DIESEL)
GLOW PLUG
(DIESEL)
31
3 R/B3 W
24
3 W/L
3 R/W
ANTI THEFTC-13 10A
3 B/Y
RELAY: LIGHTING
3 B/R
RELAY; FUEL PUMP
42
TAIL
5 W
2 W
AIR CON
RELAY; HEATER & A/C
24
3 W
3 L/R
C-21 10ASRS
FUSE BOX
C-22 10A
F-12 15A
ECM
D08RV551