battery replacement ISUZU TROOPER 1998 Service Repair Manual

GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the
front or rear wheels before lifting the vehicle.
2. Use covers on the vehicle body, seats, and
floor to prevent damage and/or
contaminations.
3. Disconnect the grounding cable from the
battery before performing service operations.
This will prevent cable damage or burning due
to shortcircuiting.
4. Raise the vehicle with a jack set against the
recommended lifting points (see ÒLifting
instructionsÓ in this section).
5. Support the vehicle on chassis stands.
6. Handle brake fluid and antifreeze solution with
great care.
Spilling these liquids on painted surfaces will
damage the paint.
7. The use of the proper tool(s) and special tool(s)
where specified is essential to efficient,
reliable, and safe service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gasket, plastic clips,
O-rings, oil seals, lock washers, and self-
locking nuts at disassembly.
Normal function of these parts cannot be
guaranteed if they are reused.
10. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct
reassembly.11. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and
design according to installation positions.
12. Clean all parts before inspection or
reassembly.
13. Clean the oil ports and other openings with
compressed air to make certain that they are
free of dirt and obstructions.
14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before
installation.
15. Use the recommended liquid gasket to prevent
leakage.
16. Carefully observe all nut and bolt torque
specifications.
17. When service operation is completed, make a
final check to be sure service has been done
properly and problem has been corrected.
18. When removing or replacing parts that require
refrigerant to be discharged from the air
conditioning system, be sure to use the
following tools to recover and recycle the
Refrigerant-134a (R-134a).
For 134a:
Use the R-134a Refrigerant Recovery/Recovery/
Recycling/Recharging/System (ACR
4) or its
equivalent to prevent the discharge of
refrigerant into the air.
0AÐ2 GENERAL INFORMATION

AIR CONDITIONING 1B Ð 13
ACR41) Using the ACR4(HFC-134a Refrigerant Recovery/
Recycling/ Recharging/ System) or equivalent to
thoroughly discharge and recover the refrigerant.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
2) Remove and replace the defective part.
3) After evacuation, charge the air conditioning
system and check for leaks.
PRECAUTIONS FOR REPLACEMENT OR REPAIR OF
AIR CONDITIONING PARTS
There are certain procedure, practices and precautions
that should be followed when servicing air conditioning
systems:
·Keep your work area clean.
·Always wear safety goggle and protective gloves
when working on refrigerant systems.
·Beware of the danger of carbon monoxide fumes
caused by running the engine.
·Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
·Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
·When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
·Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or
parts are reconnected or installed.
·When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
·Always install new O-rings whenever a connection is
disassembled.
·Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
·When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
ON-VEHICLE SERVICE

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 – 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 – 60 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
COMBINATION SWITCH REPLACEMENT
32
1
74 5 6
Removal Steps
1. Front console assembly
2. Lower cluster assembly
3. Steering lower cover
4. Inflator module
5. Steering wheel
6. Steering column cover
7. Combination switch and
SRS coil assembly
Installation Steps
7. Combination switch and
SRS coil assembly
6. Steering column cover
5. Steering wheel
4. Inflator module
3. Steering lower cover
2. Lower cluster assembly
1. Front console assembly
431RT001
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:
The wheels of the vehicle must be straight ahead and the
steering column in the "LOCK" position before
disconnecting the steering wheel. Failure to do so will
cause the coil assembly to become uncentered which will
cause damage to the coil assembly.

2A – 64 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
LOCK CYLINDER REPLACEMENT
1
5
4
6
78911
10
3
2
Removal Steps
1. Front console assembly
2. Lower cluster assembly
3. Steering lower cover
4. Inflator module
5. Steering wheel
6. Steering column cover
7. Combination switch and
SRS coil assembly
8. Snap ring
9. Cushion rubber
10. Shift lock cable (for A/T)
11. Lock cylinder assembly
Installation Steps
11. Lock cylinder assembly
10. Shift lock cable (for A/T)
9. Cushion rubber
8. Snap ring
7. Combination switch and
SRS coil assembly
6. Steering column cover
5. Steering wheel
4. Inflator module
3. Steering lower cover
2. Lower cluster assembly
1. Front console assembly
431RT003
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.

ENGINE COOLING6B±7
Water Pump
Water Pump and Associated Parts
030RS002
Legend
(1) Timing Belt
(2) Idle Pulley(3) Water Pump Assembly
(4) Gasket
Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt. Refer to ªTiming Beltº in this
manual.
5. Remove Idle pulley.
6. Remove water pump assembly.
7. Remove gasket.
Inspection
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection. Should any of
the following problems occur, the entire water pump
assembly must be replaced:

Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket
before installation.2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N´m (2.5 Kg´m/18 lb ft)

Tightening order
The tightening order are in the illustrate.
NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bolt
thread.
030RW008

6B±8
ENGINE COOLING
3. Idle pulley

Install idle pulley and tighten bolt to the specified
torque.
Torque: 52 N´m (5.3 Kg´m/38 lb ft)4. Timing belt

Install timing belt. Refer to timing belt installation
step in ªTiming Beltº in this manual.
5. Connect radiator inlet hose and replenish EC.
6. Connect battery ground cable.
Thermostat
Thermostat and Associated Parts
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a water±filled container using
thin wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
031RS003Confirm the temperature when the valve first begins to
open.
Valve opening temperature 74.5C ~ 78.5
C
(166.1
F ~ 173.3
F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90
C (194
F)
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
Torque: 25 N´m (2.5 Kg´m/18 lb ft)
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.

ENGINE ELECTRICAL6D1±1
ENGINE
ENGINE ELECTRICAL
CONTENTS
Service Precaution 6D1±1. . . . . . . . . . . . . . . . . . . . . .
Battery 6D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D1±2. . . . . . . . . . . . . . . . . . . .
Diagnosis 6D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging 6D1±3. . . . . . . . . . . . . . . . . . . . . . Jump Starting 6D1±3. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal 6D1±4. . . . . . . . . . . . . . . . . . . . . .
Battery Installation 6D1±4. . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D1±5. . . . . . . . . . .
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.

6E±76
ENGINE DRIVEABILITY AND EMISSIONS
No Malfunction Indicator Lamp (MIL)

 
StepNo Ye s Value(s) Action
14Locate and repair the open PCM battery feed circuit.
Is the action complete?
ÐVerify repairÐ
15Locate and repair the short to ground in the PCM
ignition feed circuit or PCM battery feed circuit.
Is the action complete?
ÐVerify repairÐ
16Locate and repair the short to ground in the ignition
feed circuit to the instrument cluster, and replace the
fuse.
Is the action complete?
ÐVerify repairÐ
17Replace the PCM.
IMPORTANT:The replacement PCM must be
programmed. Refer to
PCM in ON-Vehicle Service for
procedures.
Is the action complete?
ÐVerify repairÐ
18Check the MIL driver circuit for a poor connection at the
instrument panel connector.
Was a problem found?
ÐVerify repair
Go to
Instrument
Panel
in
Electrical
Diagnosis