bulb ISUZU TROOPER 1998 Service Repair Manual

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 values must
be used when installing fasteners that
require it. If the above conditions are not
followed, parts or system damage could
result.
HEATING AND VENTILATION 1A Ð 1
SECTION 1A
HEATING AND VENTILATION
CONTENTS
PAGE
General Description.....................................................1AÐ 2
Heater...............................................................1AÐ 2
Control Lever Assembly................................................1AÐ 3
Ventilation...........................................................1AÐ 3
Air Select Knob.......................................................1AÐ 4
Air Source Select Lever................................................1AÐ 4
Fan Control Knob.....................................................1AÐ 4
Temperature Control Knob.............................................1AÐ 4
Ceramic Heater.......................................................1AÐ 5
On-Vehicle Service......................................................1AÐ 6
Heater Unit..........................................................1AÐ 6
Heater Core and/or Mode Door..........................................1AÐ 8
Heater Mode Control Link Unit..........................................1AÐ10
Heater Temperature Control Link Unit....................................1AÐ12
Blower Assembly.....................................................1AÐ14
Blower Link Unit and/or Mode Door......................................1AÐ16
Blower Motor........................................................1AÐ18
Rear Heater Duct, Defroster Nozzle and Ventilation Duct....................1AÐ20
Center and/or Side Vent...............................................1AÐ22
Control Lever Assembly and/or Control Cables............................1AÐ24
Control Panel Illumination Bulb..........................................1AÐ27
Resistor.............................................................1AÐ28
Ceramic Heater and/or Full Hot Switch...................................1AÐ30

HEATING AND VENTILATION 1A Ð 27
Removal Steps
1. Control lever assembly
2. Bulb socket
3. Illumination bulb
Installation Steps
To install, follow the removal steps in the
reverse order.
CONTROL PANEL ILLUMINATION BULB
2 3 1
REMOVAL
Preparation:
Disconnect the battery ground cable
1. Control Lever Assembly
Refer to ÒCONTROL LEVER ASSEMBLYÓ removal
procedure in this section.
2. Bulb Socket
Pull out the socket from the panel by turning it
counterclockwise.
3. Illumination Bulb
Pull the illumination bulb from socket.
INSTALLATION
To install, follow the removal steps in the reverse order.

AIR CONDITIONING 1B Ð 1
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 values must
be used when installing fasteners that
require it. If the above conditions are not
followed, parts or system damage could
result.
SECTION 1B
AIR CONDITIONING
CONTENTS
PAGE
General Description.....................................................1BÐ 3
Air Conditioning Refrigerant Cycle Construction...........................1BÐ 3
Compressor.........................................................1BÐ 4
Magnetic Clutch......................................................1BÐ 5
Receiver/Drier.......................................................1BÐ 5
Dual Pressure Switch.................................................1BÐ 6
Triple Pressure Switch................................................1BÐ 6
Expansion Valve......................................................1BÐ 6
Evaporator..........................................................1BÐ 7
Electronic Thermostat.................................................1BÐ 7
Refrigerant Line......................................................1BÐ 7
Service Charge Valve..................................................1BÐ 7
Air Conditioning Parts.................................................1BÐ 8
On-Vehicle Service......................................................1BÐ 13
Precautions For Replacement or Repair of Air Conditioning Parts.............1BÐ 13
Compressor Assembly and Associated Parts..............................1BÐ 23
Condenser Assembly (LHD V6 without Condenser Fan).....................1BÐ 33
Condenser Fan Motor.................................................1BÐ 35
Receiver/Drier.......................................................1BÐ 37
Pressure Switch......................................................1BÐ 39
Evaporator Assembly.................................................1BÐ 42
Evaporator Core and/or Expansion Valve.................................1BÐ 44
Electronic Thermostat.................................................1BÐ 47
A/C Switch and Illumination Bulb.......................................1BÐ 48
Refrigerant Line......................................................1BÐ 49
Rear Cooler Parts.....................................................1BÐ 51

1B Ð 48 AIR CONDITIONING
1
2
3
Removal Steps
1. Control lever assembly
2. A/C switch
3. Illumination bulb
Installation Steps
To install, follow the removal steps in the
reverse order.
A/C SWITCH AND ILLUMINATION BULB
REMOVAL
Preparation:
Disconnect the battery ground cable
1. Control Lever Assembly
Refer to Section 1A ÒCONTROL LEVER ASSEMBLYÓ
removal procedure.
2. A/C Switch
Raise up the catch portion of the switch and remove
the switch while pushing it toward the outside.
3. Illumination Bulb
Turn the illumination bulb counterclockwise to
remove.
Catch portion
End of switch A/C switch
INSTALLATION
To install, follow the removal steps in the reverse order.

AIR CONDITIONING 1BÐ97
TROUBLESHOOTING WITH SELF-DIAGNOSIS FUNCTION
1. Overview of Self-Diagnosis Function
The self-diagnosis is implemented in 3 steps for each target. For detail of check procedure contained in
each step, refer to the relevant section of "Check Procedure by Failed Location" listed in the Self-
Diagnosis Operation Procedure.
For turning on the self-diagnosis function and switching of the check step, refer to the flow chart given
below. You can reset the self-diagnosis function by turning the ignition switch off or turning the DEF
switch on for 3 seconds.
2. Self-Diagnosis Operation Procedure
While holding both the Auto switch and the DEF switch on the
automatic heater/air conditioner panel, turn the IG off and then
on.

Does the A/C LED flash every 0.5 second interval?
Press the A/C switch once.
(The past trouble
diagnosing function will
be turned on.)

Does the A/C LED flashes every 0.5 seconds?

Does each output equipment functions normally according to
operation of the temperature setting lever?
Press the DEF switch for 3
seconds consecutively or turn on
and off the IG.
Failure on the
output equipment
or the harness.
Preparations
(1) Set the IG to the OFF mode.
(2) Apply 60W bulb light to the sun sensor.
(3) Set the temperature setting lever on the automatic heater/air
conditioner panel to the center position (25C).
(4) Set the fan switch on the same panel to the Auto position.
End of the self-diagnosis.(The current trouble diagnosing function will be turned on
approximately in 10 seconds.)
YESNO
YESNO
NO
YES
Refer to *1.
Refer to *2.

1BÐ98 AIR CONDITIONING
*1. Displaying the Current Trouble Diagnosing Table
Start the engine while holding down both the Auto switch and the DEF switch on the control panel, and
the table will appear in approximately 10 seconds to the indicator lamp (LED) of the air conditioning
switch. Result of the diagnosis along the following 9 items will be shown one by one in 0.5 second
interval irrespective of presence or absence of a trouble for a given item. When the display 9 items is
completed, it is repeated with 3 seconds of interval in between. A failed item is indicated by flashing of
the LED that is repeated 3 times within 0.5 seconds. If a trouble is indicated, you can locate the failed
section by knowing when in the total sequence it has been displayed.
Items for Current Trouble Diagnosis
As shown above, display of result along nine items is repeated with 3-second interval in between.
Note 1: When checking the solar radiation sensor, apply sufficient light using a 60W bulb.
Otherwise, it can be diagnosed as failed.
Note 2: If the temperature setting lever is set on both ends (one set to 18¡C, blue scale = Full cool and
the other to 31¡C, red scale = Full hot), they can be diagnosed as failed.
Note 3: Likewise, the fan switch can be diagnosed as failed if set on both ends.
LED on
LED off Indication for presence
of a troubleIndication for normal state
0.5 0.5 0.5
3 seconds interval
ON
OFF
Display pattern Failed part
Normal pattern
In car sensor
Ambient sensor
Sun sensor (Note 1)
Duct sensor
Temperature control lever (Note 2)
Fan switch (Note 3)
Mix actuator
Mode (blow port) control
Intake (fresh air/interior air switching) control
F01RX010
F01RY00008

00 – 10 SERVICE INFORMATION
Problem Possible Cause Correction
STEERING COLUMN (CONT.)
TURN SIGNAL SWITCH
This troubleshooting covers mechanical problems only. See Section 8 for turn signal switch electrical
diagnosis.
Turn Signal Will Not Stay
in Turn Position
Turn Signal Will Not
Cancel
Turn Signal Difficult to
Operate
Turn Signal Will Not
Indicate Lane Change
Hezard Switch Cannot Be
Turned Off
No Turn Signal Lights
Front or Rear Turn Signal
Lights Not Flashing1. Foreign material or loose parts
preventing movement of yoke.
2. Broken or missing detent or canceling
spring.
1. Loose switch mounting screws.
2. Switch or anchor bosses broken.
3. Broken, missing or out of position
detent, return or canceling spring.
4. Worn canceling cam.
1. Turn signal switch arm loose.
2. Yoke broken or distorted.
3. Loose or misplaced springs.
4. Foreign parts and/or material.
5. Loose turn signal switch mounting
screws.
1. Broken lane change pressure pad or
spring hanger.
2. Broken, missing or misplaced lane
change spring.
3. Base of wire damaged.
1. Foreign material between hazard
switch to turn signal switch body.
1. Electrical failure in chassis harness.
2. Inoperative turn signal flasher unit.
3. Loose chassis harness connector.
1. Burned-out damaged turn signal bulb.
2. High resistance connection to ground
at bulb socket.
3. Loose chassis harness connector.Repair or replace signal switch.
Replace signal switch.
Tighten mounting screws.
Replace turn signal switch.
Replace turn signal switch.
Replace turn signal switch.
Tighten arm screw.
Replace turn signal switch.
Replace turn signal switch.
Repair turn signal switch.
Tighten mounting screws.
Replace turn signal switch.
Replace turn signal switch.
Replace turn signal switch.
Repair or replace hazard
switch.
Refer to Section 8 “Electrical
Troubleshooting”.
Replace flasher unit.
Repair loose connector.
Replace bulb.
Repair bulb socket.
Repair loose connector.

4B1±11 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Functions of Indicator Lamp
Indication of vehicle condition : Indicator lamp is
controlled by 4WD control unit and shows vehicle
conditions as below.
Indicator
Vehicle condition4WD switchTransfer position
switchFront axle switch
Off2WDOff (Close)2WD (Open)2WD (Open)
On4WDOn (Open)4WD (Close)4WD (Close)
Blink (2Hz)OperatingOn (Open)4WD (Close)2WD (Open)
Off (Close)2WD (Open)4WD (Close)
Blink (4Hz)Stop operatingOn (Open)2WD (Open)2WD (Open)
Off (Close)4WD (Close)4WD (Close)
Bulb check :To check the bulb of indicator lamp, the
indicator lamp comes on when ignition key is turned on,
and goes off when the engine is started.
Retrials from 2WD to 4WD :In cold weather or under
high speed condition, the gear shifting (engagement)sometimes does not complete by 3 trials. In such case,
the indicator lamp inform driver of this incident as
aforementioned chart (shown at Retrial in Outline of shift
on the fly system).
Diagnosis
Before Judging That Troubles Occur
(Unfaulty mode)
When Switching from 2WD to 4WD
1.In case that blinking frequency of the 4WD
indicator changes from 2Hz to 4Hz.
When heavy synchronization load is needed, the
motor actuator tries the shifting transfer gear three
times including the activation shifting. While the
motor actuator tries shifting, the indicator blinks by
2Hz. If the third shifting fails, the indicator's blinking
changes from 2Hz to 4Hz at the same time that the
motor actuator shifted back to 2WD.
Heavy synchronization load occurs by:

extremely lower temperature.

higher speed, rotation difference of wheels during
cornering.
Solution 1: Operate again after stop the vehicle or
slow down.
2.In case that the 4WD indicator continues blinking
by 2Hz for more than 11.5 seconds.
When there is rotation difference of wheels or there
is phase difference between front wheels and axles,
it is difficult to connect front wheels to front axles. The
blinking by 2Hz shows that shifting the transfer gear
or connecting the front wheels is in the middle of
operating. In above case, the indicator's blinking by
2Hz shows that connecting the front wheels is not
completed (because the indicator's blinking changes
to 4Hz when the shifting transfer gear is impossible.).
And removal of rotation or phase difference make
connecting the front wheels possible.
Solution 2: When vehicle is running, drive
straight ahead while accelerating and
decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.When switching from 4WD to 2WD
1.In case that the 4WD indicator continues blinking
by 2Hz .
The 4WD indicator continues blinking by 2Hz until
both shifting the transfer gear and disconnecting the
front wheels are completed when switching 4WD to
2WD. When driveline is loaded with torsional torque,
the shifting transfer gear and disconnecting front
wheels are impossible. In this case, removal of
torsional torque on driveline make the shifting
transfer gear and disconnecting front wheels
possible.
Solution 3: When vehicle is running, drive
straight ahead while accelerating and
decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.
2.In case that the 4WD indicator's blinking changes
from 2Hz to 4Hz.
Check the position of transfer lever. Is it at ª4Lº
position? In view of the shifting mechanism of
transfer, the gear shifting from 4WD to 2WD at ª4Lº
condition is impossible.
Solution 4: Push the 4WD switch to 4WD, shift the
transfer lever to ªHighº position and re±operate
the 4WD switch to 2WD.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±6
High-Low Planetary Gear Set
Establishes an auxiliary transmission mechanism. When
the transfer shift lever is set to the 2H or TOD position, the
reduction gear ratio is 1.000 and the corresponding
driving force is generated. When the transfer shift lever is
set to the 4L position, the reduction gear ratio is 2.480 and
the corresponding driving force is generated.
262RW030
4H and 4L Switches
Detects the shift position of the transfer from the
movement of the transfer lever and outputs signals to the
TOD control unit.
261RW002
Transfer Connector
Transmits the input and output signals of the speed
sensors, electromagnetic coil, and 4H and 4L switches to
the vehicle harness. A waterproof 12-pin type is used.
261RW046
TOD Indicator Lamps (on the instrument
panel)
Inform the following items.

Bulb check

Drive mode

ABS IN status

BRAKE ON status
821RW049

4B2±7 DRIVE LINE CONTROL SYSTEM (TOD)
Check Lamp
Inform the following items.

Bulb check

Fail (fail alarm)

Trouble code

Diesel/gasoline MAP
821RW078
TOD ECU
This control unit is mounted to the front right hand seat via
a special bracket.
F07RW029