key ISUZU TROOPER 1998 Service Repair Manual

SUPPLEMENTAL RESTRAINT SYSTEM9J±25
TO ANY POWER SOURCE BEFORE CONNECTING
DEPLOYMENT WIRES TO THE PRETENSIONER
SEAT BELT ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND NOT BE
CONNECTED TO A POWER SOURCE UNTIL THE
PRETENSIONER SEAT BELT IS TO BE DEPLOYED.
THE PRETENSIONER SEAT BELT ASSEMBLY WILL
IMMEDIATELY DEPLOY THE PRETENSIONER SEAT
BELT WHEN A POWER SOURCE IS CONNECTED TO
IT. WEAR SAFETY GLASSES THROUGHOUT THIS
ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
1. Turn ignition switch to ªLOCK,º remove key and put
on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect pretensioner seat belt assembly, yellow
2±pin connector located at the base of the seat.
4. Prepare SRS deployment harness.
5. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
6. Deployment harness shall remain shorted and not be
connected to a power source until the pretensioner
seat belt is to be deployed.
7. Route deployment harness out the driver side of the
vehicle.
8. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
9. Stretch the SRS deployment harness to their full
length.
10. Connect the deployment harness to the pretensioner
seat belt assembly, yellow 2-pin connector at the
base of the seat.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS
TO BE DEPLOYED. THE PRETENSIONER SEAT
BELT ASSEMBLY WILL IMMEDIATELY DEPLOY THE
PRETENSIONER SEAT BELT WHEN A POWER
SOURCE IS CONNECTED TO IT. CONNECTING THE
DEPLOYMENT WIRES TO THE POWER SOURCE
SHOULD ALWAYS BE THE FINAL STEP IN THE
PRETENSIONER SEAT BELT ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED COULD
RESULT IN PERSONAL INJURY.
11. Notify all people in the immediate area that you intend
to deploy the pretensioner seat belt. The deployment
will be accompanied by a substantial noise which may
startle the uninformed.
12. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the pretensioner seat belt deploys, the
rapid gas expansion will create a substantial noise. Notify
all people in the immediate area that you intend to deploy
the pretensioner seat belt.13. Connect the SRS deployment harness wires to a
power source to immediately deploy the pretensioner
seat belt assembly. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle battery is
suggested.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS
TO IS TO BE DEPLOYED. THE PRETENSIONER
SEAT BELT ASSEMBLY WILL IMMEDIATELY
DEPLOY THE PRETENSIONER SEAT BELT WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES SHOULD
ALWAYS BE THE FINAL STEP IN THE
PRETENSIONER SEAT BELT ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED COULD
RESULT IN PERSONAL INJURY.
14. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
15. Disconnect the deployment harness to the
pretensioner seat belt assembly, yellow 2-pin
connector at the base of the seat.
16. In the unlikely event that the pretensioner seat belt
assembly did not deploy after following these
procedures, proceed immediately with Steps 18
through 19. If the pretensioner seat belt assembly
deployed as intended, proceed with Steps 14 through
17.
17. With both air bags and pretensioner seat belt
deployed, the vehicle may be scrapped in the same
manner as a non±SRS equipped vehicle.
NOTE: The remaining steps are to be followed in the
unlikely event that the pretensioner seat belt assembly
did not deploy after following these procedures.
18. Remove the undeployed pretensioner seat belt
assembly (s) from the vehicle. For pretensioner seat
belt assembly refer to in the ªPretensioner Seat Belt
Assembly Removalº in this manual.
19. Temporarily store the pretensioner seat belt
assembly with the deployment device facing up, away
from the surface upon which it rests.

SUPPLEMENTAL RESTRAINT SYSTEM 9J±30
Service Precautions for SRS
Component Service
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 value must be used when
installing fasteners that require it. If the above
conditions are not followed, parts or system damage
could result.
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
The SDM in Driver±Passenger SRS can maintain
sufficient voltage to cause a deployment for up to 15
seconds after the ignition switch is turned ªOFF,º the
battery is disconnected, or the fuse powering the SDM is
removed.
Many of the service procedures require removal of the
ªC±21º fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected from
the deployment loop as noted in the ªDisabling the SRSº
procedure that follows, service can begin immediately
without waiting for the 15 second time period to expire.
Disabling The SRS
Removal
Turn the ignition switch to ªOFFº and turn the steering
wheel so that the vehicle's wheels are pointing straight
ahead.
1. Remove SRS fuse ªC±21º from left dash side lower
fuse block or disconnect battery.
2. Disconnect yellow 2±pin connector at the base of
steering column.
3. Remove glove box assembly; Refer to ªPassenger air
bag assembly replacementº in this section.
4. Disconnect passenger air bag assembly yellow 2±pin
connector behind the glove box assembly.
CAUTION: W i t h t h e ª C±21º fuse removed and
ignition switch ªON,º the ªAIR BAGº warning lamp
will be ªON.º This is normal operation and does not
indicate an SRS malfunction.
Enabling The SRS
Installation
Turn ignition switch to ªLOCKº and remove key.
1. Connect yellow 2±pin connector passenger air bag
assembly.2. Install glove box assembly. Refer to ªPassenger Air
Bag Assembly Replacementº in this section.
3. Connect yellow 2±pin connector at the base of the
steering column.
4. Install ªAIR BAGº fuse ªC±21º to left dash side lower
fuse block or connect battery.
Turn ignition switch to ªONº and verify that the ªAIR BAGº
warning lamp turn on 3.5 seconds and then turns ªOFF.º If
it does not operate as described, perform the ªSRS
Diagnostic System Checkº in this section.
Handling / Installation / Diagnosis
1. Air bag assembly should not be subjected to
temperatures above 93
C (200
F).
2. Air bag assembly, and SDM should not be used if they
have been dropped from a height of 100 centimeters
(3.28 feet) or more.
3. When a SDM is replaced, it must be oriented with the
arrow on the SDM pointing toward the front of the
vehicle. It is very important for the SDM to be located
flat on the mounting surface, parallel to the vehicle
datum line. It is important that the SDM mounting
surface is free of any dirt or other foreign material.
4. Do not apply power to the SRS unless all components
are connected or a diagnostic chart requests it, as
this will set a diagnostic trouble code.
5. The ªSRS Diagnostic System Checkº must be the
starting point of any SRS diagnostics. The ªSRS
Diagnostic System Checkº will verify proper ªAIR
BAGº warning lamp operation and will lead you to the
correct chart to diagnose any SRS malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacements.
Inspections Required After An Accident
CAUTION: C e r t a i n S R S c o mponents must be
replaced after a frontal crash involving air bag
deployment.
In all types of accidents regardless of ªAir Bagº
deployment, visually inspect all of the following
components and replace as required:
Ð Driver air bag assembly
Ð Passenger air bag assembly
Ð Driver pretensioner assembly
Ð Passenger pretensioner assembly
Ð Steering wheel
Ð SRS coil assembly
Ð Steering column
Ð Knee bolster and instrument panel mounting
attachments
Ð Driver seat and belt
Ð Passenger seat and belt
Ð SDM
SDM always should be checked according to ªSDM
Replacement Guidelines.º

SUPPLEMENTAL RESTRAINT SYSTEM9J±33
Sensing And Diagnostic Module (SDM)
Service Precautions
WARNING:DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SDM. NEVER
STRIKE OR JAR SDM. UNDER SOME
CIRCUMSTANCES, IT COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY
OR IMPROPER OPERATION OF THE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . SDM
MOUNTING BRACKET BOLTS MUST BE
CAREFULLY TORQUED TO ASSURE PROPER
OPERATION. NEVER POWER UP THE SRS WHEN
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE.
THE SDM COULD BE ACTIVATED WHEN POWERED
WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE
WHICH COULD CAUSE DEPLOYMENT AND RESULT
IN PERSONAL INJURY.
WARNING: PROPER OPERATION OF THE SENSING
AND DIAGNOSTIC MODULE (SDM) REQUIRES THE
SDM TO BE RIGIDLY ATTACHED TO THE VEHICLE
STRUCTURE AND THAT THE ARROW ON THE
SENSOR BE POINTING TOWARD THE FRONT OF
THE VEHICLE.
SDM is specifically calibrated and is keyed to the SDM
location SRS wiring harness. Caution should be used to
ensure proper location of the SDM. The keying of the
SDM to its location and wiring harness connectors should
never be modified in the field.
Removal
1. Disable the SRS (Refer to ªDisabling the SRSº in this
section).
2. Remove the transmission knob (for M/T) and transfer
lever knob.
3. Remove the front console assembly and disconnect
wiring harness connector.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SDM
harness connector.
5. Remove the three SDM fixing bolts and remove SDM.
827RW044
Legend
(1) SDM
(2) SRS Harness
(3) Connector Position Assurance
Installation
1. Install the SDM on bracket and fixing bolts and tighten
the fixing bolts to the specified torque.
Torque: 10 N´m (1.0 Kg´m/87 Ib in)
2. Connect the SDM harness connector and after that,
put CPA into connector.
3. Install the front console.
4. Install the transmission knob (for M/T) and transfer
lever knob.

SUPPLEMENTAL RESTRAINT SYSTEM9J±49
10. Install glove box cover.
11. Install glove box assembly with lid.
12. Install ECM and SDM cover.
13. Install rear console assembly and connect harness
connector.14. Install front console assembly.
15. Install gear control knob.
16. Enable the SRS (Refer to ªEnabling the SRSº in this
section).
Pretensioner Seat Belt (If so equipped)
Service Precaution
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND THE PRETENSIONER SEAT BELT OR THE
PRETENSIONER SEAT BELT WIRING, FOLLOW THE
PROCEDURES LISTED BELOW TO TEMPORARILY
DISABLE THE PRETENSIONER SEAT BELT.
FAILURE TO FOLLOW PROCEDURES COULD
RESULT IN POSSIBLE THE PRETENSIONER SEAT
BELT DEPLOYMENT, PERSONAL INJURY OR
OTHERWISE UNNEEDED THE PRETENSIONER
SEAT BELT REPAIR.
AS A PRECAUTION, WEAR GLOVES AND SAFETY
GLASSES WHEN PERFORMING THE
PRETENSIONER SEAT BELT. WHEN DEPLOY A LIVE
PRETENSIONER SEAT BELT AT OUTSIDE THE
VEHICLE, DEPLOYMENT HARNESS SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS
TO BE DEPLOYED. THE PRETENSIONER SEAT
BELT WILL IMMEDIATELY DEPLOY WHEN A POWER
SOURCE IS CONNECTED TO IT. CONNECTING THE
DEPLOYMENT HARNESS SHOULED ALWAYS BE
THE FINAL STEP IN THE PRETENSIONER SEAT
BELT DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
COULD RESULT IN PERSONAL INJURY.
Parts Location
760RW028
Legend
(1) Seat
(2) Pretensioner Cover
(3) Bolt
(4) Pretensioner Harness
(5) Pretensioner
Removal
1. Turn ignition switch to ªLOCKº, remove key.
2. Remove the foot rest located behind the seat.
3. Remove the cover on seat slide.
4. Disconnect the 2-pin connector at the base of the
seat.
5. Remove four fixing bolts the seat slide and remove
seat.
6. Remove the pretensioner seat belt cover.
7. Remove the pretensioner seat belt assembly.
Installation
1. Install the pretensioner seat belt assembly.
2. Install the pretensioner seat belt cover.
3. Install the seat on seat slide and four fixing bolts.
4. Connect the yellow 2-pin connector at the base of the
seat.
5. Install the cover on seat slide.
6. Install the foot rest located behind the seat.