warning ISUZU TROOPER 1998 Service Repair Manual

GENERAL INFORMATION 0AÐ1
SECTION 0A
GENERAL INFORMATION
CONTENTS
PAGE
General Repair Instructions...............................................0AÐ 2
How To Use This Manual.................................................0AÐ 3
Identification...........................................................0AÐ 6
Lifting Instructions......................................................0AÐ 8
Torque Specifications....................................................0AÐ10
Recommended Liquid Gasket.............................................0AÐ11
Recommended Thread Locking Agents.....................................0AÐ11
Abbreviations Charts....................................................0AÐ12
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.

MAINTENANCE AND LUBRICATION 0BÐ1
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
PAGE
Maintenance Schedule...................................................0BÐ 2
Recommended Fluids, Lubricants and Fuels.................................0BÐ 7
Oil Viscosity Chart.......................................................0BÐ10
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.

1B Ð 16 AIR CONDITIONING
WARNING
·SHOULD HFC-134a CONTACT YOUR EYE(S),
CONSULT A DOCTOR IMMEDIATELY.
·DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER
OVER THE AFFECTED AREA TO GRADUALLY
RAISE THE TEMPERATURE OF THE
REFRIGERANT ABOVE THE FREEZING POINT.
·OBTAIN PROPER MEDICAL TREATMENT AS
SOON AS POSSIBLE. SHOULD THE HFC-134a
TOUCH THE SKIN, THE INJURY MUST BE
TREATED THE SAME AS SKIN WHICH HAS
BEEN FROSTBITTEN OR FROZEN.
REFRIGERANT RECOVERY
The refrigerant must be discharged and recovered by
using ACR4(HFC-134a Refrigerant Recovery/ Recycling/
Recharging/ System) or equivalent before removing or
mounting air conditioning parts.
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)
1) Connect the high and low charging hoses of the ACR
4
(or equivalent) as shown
2) Recover the refrigerant by following the ACR4
ManufactureÕs Instructions.
3) When a part is removed, put a cap or a plug on the
connecting portion so that dust, dirt or moisture
cannot get into it.
ACR4
(Low side) (High side)
HFC 134a
REFRIGERANT RECYCLING
Recycle the refrigerant recovered by ACR4or equivalent.
For the details of the actual operation, follow the steps in
the ACR
4ManufactureÕs Instructions.
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)

1B Ð 20 AIR CONDITIONING
1) Make sure the evacuation process is correctly
completed.
2) Connect the center-hose of the manifold gauge to the
refrigerant container.
·Turn the charge valve handle counterclockwise to
purge the charging line and purge any air existing
in the center-hose of the manifold gauge.
3) Open the low-pressure hand valve and charge the
refrigerant about 200 g(0.44 lbs.).
·Make sure the high-pressure hand valve is closed.
·Avoid charging the refrigerant by turning the
refrigerant container upside down.
4) Close the low-pressure hand valve of the manifold
gauge.
·Check to ensure that the degree of pressure does
not charge.
5) Check the refrigerant leaks by using a HFC-134a leak
detector.
·If a leak occurs, repair the leak connection, and
start all over again from the first step of
evacuation.
6) If no leaks are found, open the low-pressure hand
valve of the manifold gauge.Then continue charging
refrigerant to the system.
·When charging the system becomes difficult:
(1) Run the engine at Idling and close the all
vehicle doors.
(2) A/C switch is ÒONÓ.
(3) Set the fan control knob (fan switch) to its
highest position.
WARNING
BE ABSOLUTELY SURE NOT TO OPEN THE HIGH-
PRESSURE HAND VALVE. SHOULD THE HIGH-
PRESSURE HAND VALVE BE OPENED, THE HIGH-
PRESSURE REFRIGERANT GAS WOULD FLOW
BACKWARD, AND THIS MAY CAUSE THE
REFRIGERANT CONTAINER TO BURST.
7) When the refrigerant container is emptied, use the
following procedure to replace it with a new
refrigerant container.
(1) Close the low pressure hand valve.
(2) Raise the needle upward and remove the charge
valve.
(3) Reinstall the charge valve to the new refrigerant
container.
(4) Purge any air existing in the center hose of the
manifold gauge.

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 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

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

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A Ð 59
INSTALLATION
4. Steering Wheel
Align the setting marks made when removing.
CAUTION:
Never apply force to the setting wheel in direction of the
shaft by using a hammer or other impact tools in an
attempt to install the steering wheel. The setting shaft is
designed as an energy absorbing unit.
3. Steering Wheel Fixing Nut
Steering Wheel Nut Torque Nám (kgám/lbáft)
34 (3.5 / 25)
2. Horn Lead
1. Inflator Module
1) Support the module and carefully connect the
module connector.
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.
NOTE:
Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire
from being pinches.
2) Secure the module with one bolt to relieve
weight on the connector wire.
3) Tighten bolts to specified sequence as figure.
Inflator module Bolt Torque Nám (kgám/lbáin)
8 (0.8 / 69)
4) Connect the yellow 2way SRS connector located
under the steering column.
5) Connect the battery ground cable.
6) 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.
3
41
2
827RS017

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A – 61
1. Front Console Assembly
1) Remove the transmission (for M/T) and transfer
control lever knob.
2) Disconnect the wiring harness connectors.
2. Lower Cluster Assembly
3. Steering Lower Cover
Remove the engine hood opening lever.
4. 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 A
ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL
INJURY MAY RESULT.
5. Steering Wheel
Apply a setting mark across the steering wheel and
shaft so parts can be reassembled in their original
position.
827RS014
827RS015
827RS016
Up
430RS004
Setting mark