clutch ISUZU TROOPER 1998 Service Repair Manual

8D – 478 WIRING SYSTEM
Circuit Diagram (RHD 4JG2)-1
D08RW803
C-69
FENDER-LHB-1 BODY-RH
BODY-LH
FRAME
ENG.5B
BODY
8B / R
8 B
+
_
P - 6
30B
P - 1
P - 5
P - 10
P - 7
P - 2
FL-1
80A MAINFL-4 30A
CONDENSER FAN
F-6 10A
RR COOLER
1
2 I-232
I-23
I-236
1A/C SW
BLOWER
MOTOR
0.5G/O
I-42 I-42
I-421 3
216
0.5
G/W 0.5 LG
C-25
C-25
0.5LG
H-141
5W
B-190.5 BR
0.5BR 0.5BR
X-5 X-5
X-5 X-5
34 RELAY ;
A/C THERMO1
2
0.5 P/G 0.5 P/G
H-41100.5
G/W0.5
G/W
0.5 BR0.5
BR
PRESSURE SW
(CONDENSER) H-2413
0.5 LG
H-16 0.5LG
0.3GY
H-416
H-51
E-31
0.5 G/O
2L/R
I-41
I-18
I-18
I-18
I-18 1.25L/O
1.25L/Y
0.85L/W 3
36
5
2 4
1 6
FAN SW HEATER BEZEL
ILLUMINATION
I-23 I-23
I-18
I-18 3
5
4
10.3 R/G0.85 G/R
ILLUMINATION
CONTROLLER (3)RELAY ; TAIL (4)
H-201 2
BLOWER
RESISTOR
I-41
I-41
I-41
I-41
2L/B
2 B
1.25B
M
B-52
1B-5
B-361
B-36
B-36 B-362
34
3L/R 3LC-19
25A BLOWERRELAY ;
HEATER AND
A/C
0.3B
ELECTRONIC
THERMOSTAT
MAGNETIC CLUTCH
0.5G/O
5W 3W
0.5 BR 1.25 L/O
0.5 LG/Y
2B
C-20 10A
AIR CON.
0.5BR
7H-16
0.3G/Y
0.3G/Y0.3G/Y5W
0.85W/G
RELAY ; CHARGE (1)
H-1310
2
H-202L/B
VSV; FICD
C-69
2 1
0.5G/O 0.5 G/O
C-167
0.5 B
H-2616
H-2616
H-514

8D – 482 WIRING SYSTEM
Circuit Diagram (LHD 4JG2)-2
D08RW826
5H-15
1
1
H-31
2
H-50 7
C-39
X - 5 X - 5
X - 5 X - 5
34 RELAY ;
A/C THERMO12
H-416 0.5 P/G
0.5 BR 0.5 G/O 0.5 G/O
0.5 G/O
0.5 G/O
0.5 LG/Y 0.5 BR
H - 51
E - 3
C-16 1
0.5B
0.5B 3 B 0.5LG/B0.5LG/B 0.5LG/B
R - 3
BODY-RR
X - 6 X - 6
X - 6
H-50
RR COOLER
CONNECTOR X - 6
RELAY ; RR COOLER
12
MAGNET CLUTCH
0.5G/W
0.5G/W
0.5G/W
H-51
0.5 BR
C - 25 C - 25DUAL PRESSURE SW
or
TRIPLE SW
2H-4110 1H-514
X-19X-19
53 3
7
0.5B
C-69
C-69
VSV;FICD
1
24
C-25
3
TRIPLE SW
4
H-51
0.5 W/R3
H-42
0.5 W/R2
0.5 W/R4
X-191
X-19
C-75
1.25L
1
H - 1217
0.3G/Y
M
2C-75
1.25B
(IF EQUIPPED)
RELAY; CONDENSER FAN CONDENSER FAN
1.25 L/O
C-25
C-39 FENDER-RH2
0.3 G/Y
0.5 LG 0.5 LG2

8D – 540 WIRING SYSTEM
Circuit Diagram (RHD 6VE1)-2
D08RW611
FRT AXLE
SWT.O.D. CONTROL UNIT3
C-16
FENDER-LHM-220.5
L/Y
0.5
G0.5
G/W0.5
G/R0.5
G/Y
0.5
LB
0.5
G/R0.5
G
0.5
G0.5
G 0.5
G/W0.5
G/R0.5
G/R0.5
G/Y0.5
LB 0.5
L/Y
0.5
L/Y 0.5
BR/R
0.5
P
0.5
Y
0.5
Y
0.5
B0.5
B
0.5
B
0.85
B0.5
L/Y
2M-225H-10
122B-68
5H-1210H-102
M-231M-233H-10B-67
5H-72
FRT SPEED
SENSOR
(TRANSFER)RR SPEED
SENSOR
(TRANSFER)CLUTCH
SOLENOID
(TRANSFER)
M-241M-24
2
A-33H-49B-67
7
6
A-314H-49B-68
12
10
A-313H-492
H-497
H-49
B-67
10
5
A-3 9
A-31
A-3 12
H-49B-68
11
8
A-3H-49B-67
4
4
VSV;
FRT AXLE(C)VSV;
FRT AXLE(D)

8H±22SECURITY AND LOCKS
Anti-theft System
General Description
The circuit consists of the starter switch, anti-theft &
keyless entry control unit, 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 (M/T),
ANTI-THEFT indicator light and mode switch (A/T).
The system operates as follows: After locking the starter
switch and removing the starter key (this sets the alarm),
if the 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 ªOFFº to ªACCº 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.
Anti-theft & Keyless Entry Control
Unit Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly.

Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly.

Refer to the Instrument Panel Assembly in Body
Structure section.
4. Disconnect the connector(2).
5. Remove four screws to remove the anti-theft &
keyless entry control unit with bracket(1).
825RW029
6. Remove two nuts from the anti-theft & keyless entry
control unit with bracket(3) to remove the anti-theft &
keyless entry controller(4).
825RW028
Anti-theft & Keyless Entry Control
Unit Installation
To install, follow the removal steps in the reverse order.
Anti-theft Indicator Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly(1).
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Refer to the Instrument Panel Assembly in Body
Structure section.
821RW024

10A±1
CRUISE CONTROL SYSTEM
CONTROL SYSTEM
CRUISE CONTROL SYSTEM
CONTENTS
Service Precaution 10A±1. . . . . . . . . . . . . . . . . . . . . .
General Description 10A±1. . . . . . . . . . . . . . . . . . . . .
Diagnosis 10A±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Switch 10A±2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 10A±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 10A±2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 10A±3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Switch 10A±3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 10A±3. . . . . . . . . . . . . . .
Adjustment 10A±3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Switch 10A±4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 10A±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 10A±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cruise Control Main Switch 10A±5. . . . . . . . . . . . . . . Removal 10A±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 10A±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cruise Control Switch (Combination Switch) 10A±5
Removal and Installation 10A±5. . . . . . . . . . . . . . .
Cruise Control Unit 10A±6. . . . . . . . . . . . . . . . . . . . . .
Removal 10A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 10A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cruise Actuator 10A±7. . . . . . . . . . . . . . . . . . . . . . . . .
Actuator Cable Diagram (LHD) 10A±7. . . . . . . . . .
Actuator Cable Diagram (RHD) 10A±7. . . . . . . . . .
Removal 10A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 10A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 10A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 10A±8. . . . . . . . . . . . . . .
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.
General Description
The cruise control keeps the vehicle running at a fixed
speed until a signal canceling this fixed speed is received .
When the main switch ªAUTO CRUISEº is turned on with
the vehicle in the running mode, the battery voltage is
applied to the control unit. When a signal from the control
switch is input to the control unit while the vehicle is in this
state, the cruise control actuator is activated to operate
the system. Also, while the system is operating, the
ªAUTO CRUISEº indicator light in the meter assembly
lights up.
1. SET/COAST Switch Function
1.Set Function: When the SET/COAST switch is
pressed and released with the main switch on, the
speed at which the vehicle is running at that moment
is stored in the memory, and the vehicle automatically
runs at the stored speed.
2.Coast-down Function: When the SET/COAST
switch is kept on while the vehicle in running, the
vehicle decelerates during that time. The speed at
which vehicle is running when the control switch is
turned off is stored in the memory, and the vehicle
automatically returns to the stored speed.
3.Tap-down Function: When the SET/COAST switch
is turned on and off instantaneously while the vehicle
is running, the vehicle decelerates a mile for each
on/off operation. The vehicle speed at which the
vehicle was running when the SET/COAST was
turned off last is stored in the memory, and the vehicle
automatically returns to this stored speed.

10A±2
CRUISE CONTROL SYSTEM
2. RESUME/ACCEL Switch Function
1.Resume Function: When the RESUME/ACCEL
switch is turned on/off after the system is temporarily
deactivated by pressing the brake or clutch pedal
while the vehicle is running, the vehicle resumes the
speed stored before the system was released, and
the vehicle automatically runs at the stored speed .
2.Accelerate Function: When the RESUME/ACCEL
switch is kept on after the system is released
completely, the vehicle accelerates its speed during
that time. The vehicle speed at which the vehicle was
running when the switch was turned off is stored in the
memory, and the vehicle automatically returns to this
speed.
3.Tap-up Function: When the RESUME/ACCEL
switch is turned on and off instantaneously while the
vehicle is running, the vehicle decelerates a mile for
each on/off operation. The vehicle speed at which the
vehicle was running when the switch was turned off
last is stored in the memory, and the vehicle
automatically returns to this stored speed.
3. CANCEL Function
1.Temporary Cancellation:

When the brake pedal is pressed.

When the clutch pedal is pressed. (M/T)

When the select lever is shifted to any position other
than ªDº, ª3º, ª2º or ªLº. (A/T)

When the cancel switch is operated.

When the vehicle speed exceeds about 20 km/h
over the vehicle speed stored in the memory.

Turning the RESUME/ACCEL switch will return the
vehicle to the speed stored in the cruise control
memory.
2.Complete Cancellation:

When the starter switch or the main switch is turned
off.

When the fail-safe function is activated.

When the vehicle speed is about 38.5 km/h.
Diagnosis
Refer to the Cruise Control System Diagnosis in Wiring
System section.
Brake Switch
Removal
1. Disconnect the battery ground cable.
2. Remove the brake switch (1).

Disconnect the connector.

Loosen the lock nuts of the switch.

Remove the switch by turning it.
310RS004
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Check to see if the brake pedal has been returned by
the return spring to the specified position.2. Turn the switch clockwise until the tip of the threaded
portion of the brake switch contacts the pedal arm.
3. Turn the switch counterclockwise until the space
between the tip of the threaded portion and the pedal
arm is 0.5 to 1.0 mm (0.02-0.04 in.) as shown in the
figure.
310RS003

10A±3
CRUISE CONTROL SYSTEM
Adjustment
1. Check to be sure that the brake pedal (3) has been
completely returned by the return spring.
2. Disconnect the switch connector.
3. Loosen the lock nut (1) of the switch (2).
4. Turn the switch clockwise until the tip of screw portion
of the brake pedal hits the pedal arm.
5. Turn the switch counterclockwise until the clearance
between the tip of the screw portion and the pedal arm
becomes 0.5 to 1.0 mm (0.02-0.04 in).
6. Tighten the lock nut.
7. Connect the switch connector.
310RW006
Clutch Switch
Removal and Installation
Refer to the Clutch Control removal and installation steps
in Clutch section.
Adjustment
1. Check to be sure that the clutch pedal (1) has been
completely returned by the return spring.
2. Disconnect the switch connector.
3. Loosen the lock nut (2) of the switch (3).
4. Push the switch by hand until the push rod cannot be
seen from the tip portion of the switch.
5. Give the switch one reverse rotation.
6. Tighten the lock nut.
7. Connect the switch connector.
203RW002

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
7A AUTOMATIC TRANSMISSION (4L30-E)
7A AUTOMATIC TRANSMISSION (AW30-40LE)
7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)
7B MANUAL TRANSMISSION (AR-5)
7B MANUAL TRANSMISSION (MUA)
7C CLUTCH