service ISUZU TROOPER 1998 Service Repair Manual

RESTRAINT CONTROL SYSTEM 9J1±36
DTC 51 Air Bag Deployment Event Commanded
WARNING:DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.
Step
ActionYe sNo
1Was the ªSRS Diagnostic System Checkº performed?
Go to Step 2
Go to the ªSRS
Diagnostic
System Checkº
2Ignition switch ªOFF.º
Have air bag assemblies deployed?Replace
components and
perform
inspections as
directed in
ªrepairs and
inspections
required after an
accidentº in this
section
Clear diagnostic
trouble codes
Repeat ªSRS
Diagnostic
System Checkº
Go to Step 3
3Inspect front of vehicle and undercarriage for sings of impact.
Were signs of impact found?Replace
components and
perform
inspections as
directed in
ªRepairs and
Inspections
Required After An
Accidentº in this
section
Clear diagnostic
trouble codes
Repeat ªSRS
Diagnostic
System Checkº
Ignition switch
ªOFFº
Replace SDM
Reconnect all
SRS system
components,
ensure all
components are
properly mounted
Repeat ªSRS
Diagnostic
System Checkº

RESTRAINT CONTROL SYSTEM 9J1±38
DTC 53 Deployment Commanded WITH Deployment Loop Fault Or Energy Reserves Out
Of Range
WARNING:DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.
Step
ActionYe sNo
1Was the ªSRS Diagnostic System Checkº performed?
Go to Step 2
Go to the ªSRS
Diagnostic
System Checkº
2Ignition switch ªOFF.º
Have air bag assembles deployed?Replace
components and
perform
inspections as
directed in
ªRepairs And
Inspections
Required After An
Accidentº in this
section
Clear diagnostic
trouble codes
Repeat the ªSRS
Diagnostic
System Checkº
Go to Step 3
3Inspect front of vehicle and undercarriage for signs of impact.
Were signs of impact found?Replace
components and
perform
inspections as
directed in
ªRepairs And
Inspections
Required After An
Accidentº in this
section
Clear diagnostic
trouble codes
Repeat ªSRS
Diagnostic
System Checkº
Ignition switch
ªOFFº
Replace SDM
Reconnect all
SRS system
components,
ensure all
components are
properly mounted
Repeat the ªSRS
Diagnostic
System Checkº

RESTRAINT CONTROL SYSTEM 9J1±42
DTC 71 Internal SDM Fault
WARNING:DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.
CAUTION: When DTC 19 or 25 has been set, it is necessary to replace the SDM. Setting DTC 19 and 25 or 51
or 53 will also cause DTC 71 to set. When a scan tool ªCLEAR CODESº command is issued and the
malfunction is no longer present, DTC 51 or 53 and DTC 71 will remain current. Ensure that the short to voltage
condition DTC 19, 25 is repaired prior to installing a replacement SDM to avoid damaging the SDM.
Step
ActionYe sNo
1Was the ªSRS Diagnostic System Checkº performed?
Go to Step 2
Go to the ªSRS
Diagnostic
System Checkº
2Note SRS ªDiagnostic System Check.º
IS DTC 19 OR 25 OR 51 OR 53 ALSO SET (CURRENT OR
HISTORY)? (REFER TO NOTICE ABOVE.)Go to DTC 19 if
DTC 19 is set
Go to DTC 25 if
DTC 25 is set
Go to DTC 51 if
DTC 51 is set
Go to DTC 53 if
DTC 53 is set
Ignition switch
ªOFFº
Replace SDM
Repeat the ªSRS
Diagnostic
System Checkº

RESTRAINT CONTROL SYSTEM 9J1±64
DTC 52 Deployment Event Commanded
WARNING:DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE PRETENSIONER
WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT
OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE PRETENSIONER. THE SDM COULD BE
ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY.
Step
ActionYe sNo
1Was the ªSRS Diagnostic System Checkº performed?
Go to Step 2.
Go to the ªSRS
Diagnostic
System Checkº
2Ignition switch ªOFF.º
Have pretensioner assemblies deployed?Replace
components and
perform
inspections as
directed in
ªrepairs and
inspections
required after an
accidentº in this
section
clear diagnostic
trouble codes
Repeat ªSRS
Diagnostic
System Checkº
Go to Step 3
3Inspect front of vehicle and undercarriage for sings of impact.
Were signs of impact found?Replace
components and
perform
inspections as
directed in
ªRepairs and
Inspections
Required After An
Accidentº in this
section
Clear diagnostic
trouble codes
Repeat ªSRS
Diagnostic
System Checkº
Ignition switch
ªOFFº
Replace SDM
Reconnect all
SRS system
components,
ensure all
components are
properly mounted
Repeat ªSRS
Diagnostic
System Checkº

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.

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
00 SERVICE INFORMATION
2A FRONT END ALIGNMENT

PAGE BACK PAGE NEXT
4JG2
4JX1 SECTION No. CONTRNTS
00 SERVICE INFORMATION
6A ENGINE MECHANICAL
6A2 4JG2-NA / 4JG2-TURBO ENGINE
6B ENGINE COOLING
6C FUEL SYSTEM
6D ENGINE ELECTRICAL
6E -
6F EXHAUST
6G -
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL
6J INDUCTION

GENERAL INFORMATION 0A–1
SECTION 0A
GENERAL INFORMATION
CONTENTS
PAGE
General Repair Instructions...............................................0A– 2
How To Use This Manual.................................................0A– 3
Identification...........................................................0A– 6
Lifting Instructions......................................................0A– 8
Torque Specifications....................................................0A–10
Recommended Liquid Gasket.............................................0A–11
Recommended Thread Locking Agents.....................................0A–11
Abbreviations Charts....................................................0A–12
Service Precaution
WARNING: THIS VEHICLE HAS 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 fasteners 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 specification.
Following these instructions can help you avoid
damage to parts and systems.