ISUZU TROOPER 1998 Service Repair Manual

STEERING LINKAGE 2A – 49
RELAY LEVER
2
2
3
6
5
4 1 hese steps are based on the LHD model.
Removal Steps
1. Nut and cotter pin
2. Bolt and nut
3. Relay lever and Bracket
4. Nut and washer
5. Relay lever
6. Bracket
Installation Steps
6. Bracket
5. Relay lever
4. Nut and washer
3. Relay lever and bracket
2. Bolt and nut
1. Nut and cotter pin
REMOVAL
Preparation:
Raise the vehicle and support the frame with suitable
safety stands.
1. Nut and Cotter pin
Disconnect relay lever at the center track rod.
Remover: 5-8840-2121-0 (J-36831)
433RW005
These steps are based on the LHD model.

2A – 50 STEERING LINKAGE
2. Bolt and Nut
Remove stabilizer bar bolts and nuts and push the
stabilizer bar aside and remove the bolts and nuts.
3. Relay Lever and Bracket
4. Nut and Washer
5. Relay Lever
Remove relay lever from the bracket.
Remover: 5-8840-0015-0 (J-22912-01)
6. Bracket
INSTALLATION
6. Bracket
5. Relay Lever
4. Nut and Washer
Relay Lever Nut Torque N·m (kg·m/lb·ft)
118 (12.0 / 87)
3. Relay Lever and Bracket
2. Bolt and Nut
Bracket Nut Torque N·m (kg·m/lb·ft)
44 (4.5 / 33)
1. Nut and Cotter Pin
Tighten the nut to the specified torque, with just
enough additional torque to align cotter pin holes.
Install new cotter pin.
Relay Lever Nut Torque N·m (kg·m/lb·ft)
59 (6.0 / 43)

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A – 51
SECTION 2A
SUPPLEMENTAL RESTRAINT SYSTEM
STEERING WHEEL & COLUMN
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.
CONTENTS
PAGE
General Description ......................................................................................................... 2A – 52
On-Vehicle Service ........................................................................................................... 2A – 53
SRS Connectors ........................................................................................................... 2A – 53
Inflator Module Replacement ..................................................................................... 2A – 54
Steering Wheel Replacement ..................................................................................... 2A – 57
Combination Switch Replacement ............................................................................ 2A – 60
Lock Cylinder Replacement ........................................................................................ 2A – 64
Steering Column Replacement .................................................................................. 2A – 69

This steering wheel and column repair section
covers the Supplemental Restraint System (SRS)
steering column. The following repair procedures
are specific to SRS Components. When servicing a
vehicle equipped with Supplemental Restraint
System, pay close attention to all WARNINGS and
CAUTIONS.
For detailed explanation about SRS, refer to Section
9J "SUPPLEMENTAL RESTRAINT SYSTEM (SRS)"
of manual.
The steering column has three important features in
addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize
the possibility of injury to the driver of the
vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition
and steering operation can be locked to
prevent theft of the vehicle.
The column may be disassembled and
reassembled. To insure the energy absorbing
action, it is important that the specified screws,
bolts and nuts be used only as designated and that
they are tightened to the specified torque.
When the column is removed from the vehicle, a
sharp blow on the end of steering shaft or shift
lever, leaning on the column assembly, or dropping
the assembly could shear or loosen the fasteners
that maintain column rigidity.
WARNING
THIS VEHICLE HAS A SUPPLEMENTAL RE-
STRAINT 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 INFORM ATION.
FAILURE TO FOLLOW WARNINGS COULD RE-
SULT IN POSSIBLE AIR BAG DEPLOYMENT,
PERSONAL INJURY, OR OTHERWISE UN-
NEEDED SRS SYSTEM REPAIRS.
SAFE HANDLING OF INFLATOR MODULES
REQUIRES FOLLOWING THE PROCEDURES
DESCRIBED BELOW FOR BOTH LIVE AND
DEPLOYED MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWEDWHEN HANDLING A DEPLOYED AIR BAG AS-
SEMBLY (AIR BAG). AFTER DEPLOYMENT,
THE AIR BAG ASSEMBLY (AIR BAG) SURFACE
MAY CONTAIN A SMALL AMOUNT OF SODIUM
HYDROXIDE, A BY-PRODUCT OF THE DEPLOY-
MENT REACTION, THAT IS IRRITATING TO THE
SKIN AND EYES.MOST OF THE POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) IS HARM-
LESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH
YOUR HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WHEN CARRYING A LIVE AIR BAG ASSEMBLY,
MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY
AN AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOY-
MENT, THE BAG WILL THEN DEPLOY WITH
MINIMAL CHANCE OF INJURY. WHEN PLACING
A LIVE AIR BAG ASSEMBLY ON A BENCH OR
OTHER SURFACE, ALWAYS FACE THE BAG AND
TRIM COVER UP, AWAY FROM THE SURFACE.
NEVER REST A STEERING COLUMN ASSEMBLY
ON THE STEERING WHEEL WITH THE AIR
BAG ASSEMBLY FACE DOWN AND COLUMN
VERTICAL.THIS IS NECESSARY SO THAT A
FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT. OTHER-
WISE, PERSONAL INJURY COULD RESULT.
TO AVOID DEPLOYMENT WHEN TROUBLE
SHOOTING THE SRS SYSTEM, DO NOT USE
ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED VOLT-
METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN SPECI-
FIED IN THIS MANUAL. DO NOT USE A NON-
POWERED PROBE-TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PER-
SONAL INJURY MAY RESULT. 2A – 52 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
GENERAL DESCRIPTION

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A – 53
ON-VEHICLE SERVICE
21
827RW035
SRS CONNECTORS
CAUTION:
The special yellow color connectors are used for
supplemental restraint system-air bag circuit.
When removing the cable harness, do not pull the cables.
Otherwise, cable disconnection may occur.
When connect the SRS connector, insert the connector
completely. Imperfect locking may cause malfunction of
SRS circuit.
REMOVAL
To remove the connector, hold the cover insulator(1) and
pull it. The cover insulator slides and lock will be released.
Do not hold the socket insulator(2).
INSTALLATION
To install the connector, hold the socket insulator(1) and
insert it. The cover insulator slides and connector will be
locked.
Do not hold the cover insulator(2).
2
1
827RW034

2A – 54 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
INFLATOR MODULE REPLACEMENT
1
3
2
Removal Steps
1. Fixing bolt
2. Module connector
3. Inflator module
Installation Steps
3. Inflator module
2. Module connector
1. Fixing bolt
827RS049
These steps are based on the LHD model.
REMOVAL
Preparation:
1) Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2) Turn the ignition switch to "LOCK".
3) Disconnect the battery ground cable, and wait at least
5 minutes.
4) Disconnect the yellow 2way SRS connector located
under the steering column.
1. Fixing Bolt
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.
827RS014

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A Ð 55
2. Module Connector
Disconnect the yellow 2way SRS connector located
behind the inflator module.
3. Inflator Module
827RS015
827RS016
INSPECTION AND REPAIR
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 URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE
AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL
INJURY MAY BE RESULT.
INSTALLATION
3. Inflator Module
CAUTION:
·Never use the air bag assembly from another vehicle.
Use only the air bag assembly for "UBS".
·When replace the inflator module, use only same parts
number assembly. If different parts number assembly is
installed, the air bag system can not function correctly
because it has different characteristic.
2. Module Connector
Support the module and carefully connect the
module connector.
NOTE:
Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire
from being pinched.
The Inflator module consists of a cover, air bag,
inflator, and retainer. Inspect the Inflator module
mainly for the following:
1) Check for holes, cracks, severe blemishes and
deformation on the cover.
2) Check that the retainer is not deformed.
3) Check for defects such as damage and breakage
in the lead wire of the squib.
If an abnormality is found as the result of the
inspection, replace the Inflator module with a new
one.
Up

2A – 56 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
3
41
2
1. Fixing Bolt
1) Secure the module with one bolt to relieve
weight on the connector wire.
2) Tighten bolts to specified sequence as figure.
N·m (kg·m/lb·in)
8 (0.8 / 69)
3) Connect the yellow 2way SRS connector located
under the steering column.
4) Connect the battery ground cable.
5) Set ignition to "ON" while watching warning
light. Light should flash 7 times and then go off.
If lamp does not operate correctly, refer to
Section 9J.
827RS017

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A – 57
STEERING WHEEL REPLACEMENT
1
3
2
4
Removal Steps
1. Inflator module
2. Horn lead
3. Steering wheel fixing nut
4. Steering wheel
Installation Steps
4. Steering wheel
3. Steering wheel fixing nut
2. Horn lead
1. Inflator module
430RS016
These steps are based on the LHD model.
REMOVAL
Preparation:
1) Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2) Turn the ignition switch to "LOCK".
3) Disconnect the battery ground cable, and wait at least
5 minutes.
4) Disconnect the yellow 2way SRS connector located
under the steering column. CAUTION:
Once the steering column is removed from the vehicle, the column is extremely suspectible to
damage. Dropping the column assembly on its end could collapse the steering shaft or loosen the
slide block which maintains column rigidity. Leaning on the column assembly could cause the jacket
to bend or deform. Any of the above damage could impair the column's collapsible design. If it is
necessary to remove the steering wheel, use only the specified steering wheel puller. Under no
conditions should the end of the shaft be hammered upon, as hammering could loosen slide block
which maintains column rigidity.

2A – 58 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
1. Inflator Module
1) 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.
2) Disconnect the yellow 2way SRS connector
located behind the inflator module.
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 URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE
AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL
INJURY MAY RESULT.
2. Horn Lead
3. Steering Wheel Fixing Nut
4. Steering Wheel
1) Apply a setting mark across the steering wheel
and shaft so parts can be reassembled in their
original position.
2) Move the front wheels to the straight ahead
position and use special tool.
Steering wheel remover: 5-8840-0016-0 (J-29752)
NOTE:
Never apply force to the steering wheel in direction
of the shaft by using a hammer or other impact tools
in an attempt to remove the steering wheel. The
steering shaft is designed as an energy absorbing
unit.
827RS014
827RS016
430RS004
Up
Setting mark