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Isuzu 2000 Trooper Workshop Manual

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Table of Contents
WORKSHOP MANUAL
TROOPER
(UX)
FOREWORD
This manual includes special notes, important points, service
data, precautions, etc. that are needed for the maintenance,
adjustments, service, removal and installation of vehicle
components.
All information, illustrations and specifications contained in
this manual are based on the latest product information
available at the time of publication.
All rights are reserved to make changes at any time without
notice.
Arrangement of the material is shown in the table of contents
on the right-hand side of this page. A black spot on the first
page of each section can be seen on the edge of the book
below each section title. These point to a more detailed table
of contents preceding each section.
This manual applies to 2000 models.
SECTION
TABLE OF CONTENTS
Click
GENERAL INFORMATION
0A
General Information
0B
Maintenance and Lubrication
HEATING, VENTILATION AND AIR CONDITIONING
1A
HVAC Systems
STEERING
2A
Power Assisted System
SUSPENSION
3C
Front Suspension
3D
Rear Suspension
3E
Wheel and Tire System
DRIVELINE/AXLE
4A1
Differential (Front)
4A2
Differential (Rear)
4B1
Driveline Control System (SHIFT ON THE FLY)
4B2
Driveline Control System (TOD)
4C
Drive Shaft System
4D1
Transfer Case (Standard Type)
4D2
Transfer Case (TOD)
BRAKE
5A
Brake Control System
5B
Anti-Lock Brake System
5C
Power-Assisted Brake System
5D
Parking Brake System
ENGINE
6A
Engine Mechanical
6B
Engine Cooling
6C
Engine Fuel
6D1
Engine Electrical
6D2
Ignition System
6D3
Starting and Charging System
6E
Driveability and Emissions
6F
Engine Exhaust
6G
Engine Lubrication
6H
Engine Speed Control System
6J
Induction
TRANSMISSION
7A
Automatic Transmission
7A1
Transmission Control System
7B
Manual Transmission
7C
Clutch
BODY AND ACCESSORIES
8A
Lighting System
8B
Wiper/Washer System
8C
Entertainment
8D
Wiring System
8E
Meter and Gauge
8F
Body Structure
8G
Seats
8H
Security and Locks
8I
Sun Roof/Convertible Top
8J
Exterior/Interior Trim
RESTRAINTS
9A
Seat Belt System
9J
Supplemental Restraint System (SRS)
9J1
Restraint Control System
CONTROL SYSTEM
10A
Cruise Control System
HOME

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  Summary of Contents for Isuzu 2000 Trooper

  • Page 1 HOME SECTION TABLE OF CONTENTS Click GENERAL INFORMATION General Information Maintenance and Lubrication HEATING, VENTILATION AND AIR CONDITIONING WORKSHOP MANUAL HVAC Systems STEERING Power Assisted System TROOPER SUSPENSION Front Suspension (UX) Rear Suspension Wheel and Tire System DRIVELINE/AXLE Differential (Front) Differential (Rear) Driveline Control System (SHIFT ON THE FLY) Driveline Control System (TOD)
  • Page 2: Table Of Contents

    The SRS system equipped vehicle can be identified efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 1. “AIR BAG” warning light on the instrument panel. 7. Used cotter pins, plastic clips, gaskets, O–rings, oil 2.
  • Page 3: Illustration Arrows

    0A–2 GENERAL INFORMATION Illustration Arrows Arrows are designed for specific purposes to aid your understanding of technical illustrations. Arrow Type Application Arrow Type Application D Ambient/Clean air flow Front of vehicle D Cool air flow D Gas other than ambient air Up Side D Hot air flow D Ambient air mixed...
  • Page 4: Identification

    GENERAL INFORMATION 0A–3 Identification Vehicle Identification Number (VIN) This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle. 905RY00002 F00RY00002...
  • Page 5 0A–4 GENERAL INFORMATION Engine Serial Number Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode The gasoline engine serial number is stamped on the left switch. rear lower area of the cylinder block above the starter. 240RW012 F06RW001 Transmission Serial Number...
  • Page 6: Theft Prevention Standard

    GENERAL INFORMATION 0A–5 Theft Prevention Standard The 11 major components listed below will be marked with 17 digit V.I.N. at the stage of production. In addition its service parts will be marked with manufacturer’s trade mark, “R” mark and “DOT” mark. INDICATION Reference COMPONENT...
  • Page 7 0A–6 GENERAL INFORMATION Anti Theft Stamping/Label/Plate Location The stamping, label and plate locations are indicated by arrows in the illustration below. NOTE: A. VIN plate locations for production. B. Stamping locations for service parts. Engine 901RW195 Manual Transmission (AR–5) 901RX021...
  • Page 8 GENERAL INFORMATION 0A–7 Automatic Transmission (THM) 901RW197 Body 901RW113 Legend (6) Fender (3) Engine Hood (7) Rear Quarfer Panel (4) Front Door (8) Front Bumper (5) Rear Door...
  • Page 9 0A–8 GENERAL INFORMATION Body 901RW114 Legend (10) Back Door Right Side (9) Back Door Left Side (11) Rear Bumper...
  • Page 10 GENERAL INFORMATION 0A–9 Body Label Instructions Do not peel off the masking tape until completion of paint work when replacing these parts, as the tape is affixed on the label attached to service parts for body of the anti–theft component. NOTE: Be sure to pull off the masking tape after paint work has been completed.
  • Page 11: Lifting Instructions

    0A–10 GENERAL INFORMATION Lifting Instructions CAUTION: D If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage. D When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or...
  • Page 12 GENERAL INFORMATION 0A–11 Lifting Point; Front Lifting Point; Rear D When using a floor jack, lift on the center of the skid D Position the floor jack at the center of the rear axle plate. case when lifting the vehicle. 545RS001 420RS002 Supportable Point;...
  • Page 13 0A–12 GENERAL INFORMATION Supportable Point; Rear D Position the chassis stands at the bottom of the rear axle case. 420RS001...
  • Page 14: Standard Bolts Torque Specifications

    GENERAL INFORMATION 0A–13 Standard Bolts Torque Specifications The torque values given in the following table should be applied where a particular torque is not specified. Strength Class Strength Class Refined Non-Refined Bolt Identification Bolt Diameter Pitch (mm) M 6X1.0 4—8 (3—6) 5—10 N·m (4—7 lb ft) —...
  • Page 15: Abbreviations Charts

    0A–14 GENERAL INFORMATION Abbreviations Charts Exh — Exhaust ° F — Degrees Fahrenheit List of automotive abbreviations which may be used Fed — Federal (All States Except Calif.) in this manual FF — Front Drive Front Engine A — Ampere(s) FL —...
  • Page 16: Service Parts Identification Plate

    GENERAL INFORMATION 0A–15 N — Newtons TVRS — Television & Radio Suppression NA — Natural Aspirated TVV — Thermal Vacuum Valve NC — Normally Closed TWC — Three Way Catalytic Converter N·M — Newton Meters 3 A/T — Three Speed Automatic Transmission/Transaxle NO —...
  • Page 17 SECTION MAINTENANCE AND LUBRICATION 0B–1 TROOPER GENERAL INFORMATION MAINTENANCE AND LUBRICATION CONTENTS Maintenance Schedule List ....0B–1 Lubricant Viscosity Chart ....0B–9 Explanation of Complete Vehicle Maintenance Recommended Liquid Gasket...
  • Page 18 MAINTENANCE AND LUBRICATION 0B–2 Mileage Only Items...
  • Page 19 MAINTENANCE AND LUBRICATION 0B–3 Mileage/Months...
  • Page 20 MAINTENANCE AND LUBRICATION 0B–4...
  • Page 21: Maintenance Schedule List

    MAINTENANCE AND LUBRICATION 0B–5 Explanation of Complete Vehicle Valve Clearance Adjustment Maintenance Schedule Incorrect valve clearance will result in increased engine noise and reduced engine output. Brief explanations of the services listed in the preceding Retorque the camshaft bearing cap bolts before checking Maintenance Scheduled are presented below.
  • Page 22 MAINTENANCE AND LUBRICATION 0B–6 Battery fluid level normal highway speeds means a wheel balancing is needed. Check tire pressure when the tires are “cold” Check fluid level in the battery. (include the spare). Maintain pressure as shown in the tire placard, which is Fluid Leak Check located on the driver’s door lock pillar.
  • Page 23 MAINTENANCE AND LUBRICATION 0B–7 crank. The starter should crank only when the clutch pedal is fully depressed. Accelerator Linkage Lubrication Lubricate the accelerator pedal fulcrum pin with chassis grease. Steering and Suspension Inspection Inspect the front and rear suspension and steering system for damaged, loose or missing parts or signs of wear.
  • Page 24: Recommended Fluids And Lubricants

    MAINTENANCE AND LUBRICATION 0B–8 Recommended Fluids and Lubricants USAGE FLUID/LUBRICANT Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil chart on the following page for proper viscosity) Mixture of water and good quality ethylene glycol base Engine coolant type antifreeze.
  • Page 25: Lubricant Viscosity Chart

    MAINTENANCE AND LUBRICATION 0B–9 Lubricant Viscosity Chart Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following table. Oil Viscosity Chart for Gasoline Engine 905RT011...
  • Page 26 MAINTENANCE AND LUBRICATION 0B–10 Oil Viscosity Chart for Manual Transmission and Transfer Case B00RW002 Oil Viscosity Chart for Front Axle B00RW003...
  • Page 27: Recommended Liquid Gasket

    Three Bond 1281 Three Bond Water Base Three Bond 1141E Three Bond For Engine Repairs Three Bond 1104 Three Bond Belco Bond 4 Isuzu Solvent For Engine Repairs Belco Bond 401 Isuzu Belco Bond 402 Isuzu LOCTITE 515 Loctite Anaerobic...
  • Page 28: Recommended Thread Locking Agents

    MAINTENANCE AND LUBRICATION 0B–12 Recommended Thread Locking Agents LOCTITE Type LOCTITE Color LOCTITE 242 Blue LOCTITE 262 LOCTITE 271 Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry.
  • Page 29: Maintenance Service Data

    MAINTENANCE AND LUBRICATION 0B–13 Maintenance Service Data Service Data and Specifications ENGINE Valve clearance (cold) Intake 0.28 0.05 mm (0.011 in) Exhaust 0.3 0.05 mm (0.015 in) Spark plug type K16PR-P11/PK16PR11/RC10PYP4 Spark plug gap 1.05 mm (0.04 in) CLUTCH Clutch pedal free play 5-15 mm (0.197-0.591 in) BRAKE Brake pedal free play...
  • Page 30 SECTION HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–1 TROOPER HEATING, VENTILATION AND AIR CONDITIONING (HVAC) HVAC SYSTEMS CONTENTS Service Precaution ..... . 1A–3 Center Vent, Drive Side Vent and Associated Parts...
  • Page 31 1A–2 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Removal ......1A–60 Full Automatic Air Conditioner Parts Configuration .
  • Page 32: Heating And Ventilation System

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...
  • Page 33 1A–4 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 840RS004 Legend (8) Duct (1) Side Defroster Hose (9) Heater Unit (2) Vent Box (10) Rear Heater Duct (3) Upper Center Vent Box (11) Lap Vent Nozzle (4) Lower Center Vent Box (12) Vent Box (5) Blower Assembly (13) Side Defroster Hose (6) Control Lever Assembly...
  • Page 34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–5 Control Lever Assembly The vehicle has cable-type-control to control the mode The fan control is used to control the amount of air sent and temperature of the heater unit and the mode door for out by the resistor at four levels from “LOW”...
  • Page 35 1A–6 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Ventilation Set “AIR SOURCE SELECT LEVER” to “FRESH” The blower fan also serves to deliver fresh outside air to position and turn on the blower fan. Heating can be done the vehicle interior to assure adequate ventilation. in this lever position, sending in fresh air from outside.
  • Page 36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–7 Air Select Knob The air select knob allows you to direct heated air into the Selecting this mode allows air conditioning system to work when the fan switch is turned to on position, passenger compartment through different outlets.
  • Page 37: Wiring Diagram

    1A–8 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Wiring Diagram D01RS005...
  • Page 38: Diagnosis

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–9 Diagnosis Heating Cycle diagnosis Condition Possible cause Correction No heating or insufficient heating. Blower motor does not run or runs Refer to “FAN CONTROL LEVER improperly. (FAN SWITCH) DIAGNOSIS”. Engine coolant temperature is low. Check engine coolant...
  • Page 39 1A–10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Fan Control Lever (Fan Switch) Diagnosis Current flows to the blower motor through the heater and For the inspection of the relays, switches and units in the A/C relay (B-36) to activate the rotation of the blower each table, refer to “INDIVIDUAL INSPECTION”...
  • Page 40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–11 Chart “A” Blower Motor Dose Not Run Step Action Is relay (B-36) OK? Go to Step 2 Replace Is fuse C-19 (25A) OK? Go to Step 3 Replace Is resistor OK? Go to Step 4 Replace Is fan control knob OK? Replace control...
  • Page 41: Individual Inspection

    1A–12 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart “E” Blower Motor Dose Not Run At High Position Step Action Is resistor OK? Go to Step 2 Replace Is fan control knob (Fan Switch) OK? Open circuit between Chassis side connector terminal No.
  • Page 42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–13 Fan switch Resistor terminals Resistance position with continuity 2.4 m 1 — 2 0.90 m 2 — 4 0.28 m 2 — 6 2 — 3 — Fan Control Knob (Fan Switch) 1. Check for continuity between the terminals of the fan switch.
  • Page 43: Removal

    1A–14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Unit Heater Unit and Associated Parts 860RY00005 Legend (7) Heater Unit Assembly (1) Instrument Panel Assembly (8) Center Ventilation Lower Duct (2) Instrument Panel Center Bracket (9) Driver Lap Vent Nozzle (3) Resistor (10) Water Hose (4) Duct (11) Electro Thermo Connector (With A/C)
  • Page 44: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–15 8. Remove evaporator assembly (A/C only). D Refer to Evaporator Assembly in this section. 9. Remove instrument panel center bracket. D Refer to Cross Beam Assembly in Body and Accessories section. 10. Remove rear heater duct. 11.
  • Page 45: Heater Core And / Or Mode Door

    1A–16 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Core and / or Mode Door Disassembled View 860RS001 Legend (4) Heater Unit (1) Case (Temperature Control) (5) Case (Mode Control) (2) Mode Door (6) Heater Core (3) Duct Removal 4. Remove heater unit. D Refer to Heater Unit in this section.
  • Page 46: Inspection

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–17 7. Remove case (Temperature control). Separate two 9. Pull out the mode door while raising up the catch of halves of core case. the door lever. 860RS002 860RS004 8. Remove heater core (1). Inspection Check for foreign matter in the heater core, stains or core fin damage.
  • Page 47: Heater Mode Control Link Unit

    1A–18 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Mode Control Link Unit Disassembled View 860RS005 Legend (4) Clip (1) Case (Mode Control) (5) Door Lever (2) Heater Unit (6) Rod (3) Mode Sub-lever (7) Washer and Mode Main Lever Removal 1.
  • Page 48: Heater Temperature Control Link Unit

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–19 Installation 2. After installing the link unit, check to see if the link unit operates correctly. To install, follow the remove steps in the reverse order, noting the following points: 1. Apply grease to the mode sub-lever and to the abrasive surface of the heater unit.
  • Page 49: Blower Assembly

    1A–20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Blower Assembly Blower Assembly and Associated Parts 873RY00003 Legend (5) Blower Assembly (1) Electro Thermo Connector (6) Duct (2) Blower Motor Connector (7) Evaporator Assembly (A/C only) (3) Resistor Connector (8) Heater Unit (4) Dash Side Trim Panel (RH) (9) Instrument Panel Assembly Removal...
  • Page 50: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–21 Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Adjust the control lever assembly cables. D Refer to Control Lever Assembly in this section. Blower Link Unit and / or Mode door Disassembled View 873RS001 Legend...
  • Page 51: Installation

    1A–22 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 4. Remove lower case. 5. Separate the upper case and slit the lining parting face with a knife. 873RS002 6. Pull out the mode door while lifting up the catch of door lever. 7.
  • Page 52: Blower Motor

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–23 Blower Motor Blower Motor and Associated Parts 873RS004 Legend (4) Fan (1) Blower Motor Connector (5) Blower Motor (2) Blower Motor Assembly (6) Attaching Screw (3) Clip Removal Installation To install, follow the removal steps in the reverse order. 1.
  • Page 53: Rear Heater Duct, Defroster Nozzle And Ventilation Duct

    1A–24 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Rear Heater Duct, Defroster Nozzle and Ventilation Duct Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts 874RS017 Legend (6) Center Console (1) Center Defroster Nozzle (7) Rear Heater Duct (2) Side Defroster Nozzle (8) Driver Lap Duct (3) Side Ventilation Duct (9) Cross Beam Assembly...
  • Page 54: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–25 10. Remove side defroster nozzle. 11. Remove center defroster nozzle. Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching.
  • Page 55: Control Lever Assembly And / Or Control Cable

    1A–26 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Control Lever Assembly and / or Control Cable Control Lever Assembly, Control Cable and Associated Parts 865RS011 Legend (7) Attaching Screws (1) Instrument Panel Passenger Lower Cover (8) Control Lever Assembly Assembly (9) Mode Control Link Connection (2) Glove Box (10) Front Console Assembly (3) Fan Switch and Air Conditioning Switch...
  • Page 56: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–27 8. Remove attaching screws. D Remove the four attaching screws. 865RS009 10. Remove control lever assembly. 11. Remove control cable. 865RS010 9. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors. Installation To install, follow the removal steps in the reverse order, noting the following points:...
  • Page 57: Control Panel Illumination Bulb

    1A–28 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D Air source control cable. 2. Connect the control cable at the “COLD” position of the temperature control link of the 1. Slide the control lever to the left (“CIRC” heater unit and secure it with the clip. position).
  • Page 58: Resistor And Associated Parts

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–29 Resistor Resistor and Associated Parts 874RW005 Legend (5) Front Console (1) Glove Box (6) Lower Cluster (2) Duct (Heater only) (7) Instrument Panel Passenger Lower Cover Assembly (3) Resistor Connector (4) Resistor Removal Installation To install, follow the removal steps in the reverse order.
  • Page 59: Air Conditioning System

    1A–30 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Air Conditioning System General Description Air Conditioning Refrigerant Cycle Construction C01RS003 Legend (9) Condenser (1) Electronic Thermostat (10) Compressor (2) Evaporator Core (11) Magnetic Clutch (3) Evaporator Assembly (12) Mode (HEAT) Control Door (4) Temperature Sensor (13) Temp.
  • Page 60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–31 evaporator vaporizes readily. The liquid refrigerant This vehicle is equipped with six-cylinder axle plate removes the required quantity of heat (latent heat of compressor (1). vaporization) from the air around the evaporator core The specified amount of the compressor oil is 240cc cooling fins and rapidly vaporizes.
  • Page 61 1A–32 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) The refrigerant line connection has a bolt at the block joint, for easy servicing. The condenser assembly (6) is located in front of the radiator. It provides rapid heat transfer from the refrigerant to the cooling fins. 875RW004 Pressure Switch The pressure switch (Dual pressure switch) (4) is...
  • Page 62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–33 Expansion Valve Evaporator This expansion valve (1) is an external pressure type and The evaporator cools and dehumidifies the air before the it is installed at the evaporator intake port. air enters the passenger compartment. High-pressure The expansion valve converts the high pressure liquid liquid refrigerant flows through the expansion valve (2) refrigerant sent from the receiver/drier to a low pressure...
  • Page 63 1A–34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) A characteristic of the sensor is that the resistance Refrigerant Line decreases as the temperature increases and the Restriction in the refrigerant line will be indicated by: resistance increases as the temperature decreases. 1.
  • Page 64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–35 Air Conditioning Parts 852RW009 Legend (7) Condenser Assembly (1) Liquid Line (High-Pressure Pipe) (8) Drive Belt (2) O-ring (9) Relay (3) Compressor (10) Drain Hose (4) Discharge Line (High-Pressure Hose) (11) Suction Line (Low-Pressure Hose) (5) Pressure Switch (12) Evaporator Assembly (6) Receiver Drier...
  • Page 65 1A–36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Wiring Diagram D08RW254...
  • Page 66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–37 D08RX003...
  • Page 67 1A–38 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D08RW256...
  • Page 68: Diagnosis

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–39 Diagnosis Air Conditioning Cycle Diagnosis Condition Possible cause Correction No cooling or insufficient cooling. Magnetic clutch does not run. Refer to “Magnetic Clutch Diagnosis” in this section. Compressor is not rotating properly. Adjust the drive belt to the specified Drive belt is loose or broken.
  • Page 69 1A–40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Checking The Refrigerant System With Manifold Gauge Since Refrigerant-134a (HFC-134a) is used in the air conditioning system in this vehicle, be sure to use manifold gauges, charging hoses and other air conditioning service tools for HFC-134a when checking the refrigerant system.
  • Page 70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–41 Connect The Manifold Gauge Low-pressure hose (LOW) — Suction side High pressure hose (HI) — Discharge side 901RS137 Legend (1) Low Side (2) High Side Condition Possible cause Correction Discharge (High Gauge) Pressure Condenser clogged or dirty.
  • Page 71 1A–42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition Possible cause Correction Discharge (High Gauge) Pressure Restriction caused by debris or Check system for restriction and Abnormally Low. moisture in the receiver/drier. replace the receiver/drier. Frost or dew on refrigerant line before and after the receiver/drier or expansion valve, and low pressure gauge indicates vacuum.
  • Page 72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–43 Condition Possible cause Correction Suction (Low Gauge) and Discharge Excessive refrigerant in system. Discharge recover (High Gauge) Pressure Abnormally refrigerant, the Recharge to the High. specified amount. Insufficient cooling. Condenser clogged or dirty. Clean the condenser fins.
  • Page 73 1A–44 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Magnetic Clutch Diagnosis D08RX004 When the air conditioning switch and the fan control knob flows through the thermostat and the compressor relay to (fan switch) are turned on with the engine running, current activate the magnetic clutch.
  • Page 74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–45 The air conditioning can be stopped by turning off the air in the prearranged conditions to reduce the engine load conditioning switch or the fan control knob (fan switch). which is being caused by the rise in the engine coolant However, even when the air conditioning is in operation, temperature, and the acceleration of the vehicle, etc.
  • Page 75 1A–46 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Magnetic Clutch Does Not Run (Cont’d) Step Action Check to see if battery voltage is present at chassis side Power train connector terminal No. C1-B14. control module (PCM) defective. Is there a battery voltage? Refer to Open circuit between No.
  • Page 76: Individual Inspection

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–47 Individual Inspection Heater And A/C (B-36), Thermostat (X-5) And Compressor (X-7) Relay Fan Control Knob (Fan Switch) And Air 1. Disconnect relays and check for continuity and Conditioning (A/C) Switch resistance between relay terminals. 1.
  • Page 77: General Repair Procedure

    1A–48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D When removing and replacing any parts which Pressure Switch require discharging the refrigerant circuit, the 1. Disconnect pressure switch connector and check for operations described in this section must be continuity between pressure switch side connector performed in the following sequence: terminals (1) and (2).
  • Page 78 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–49 CAUTION: Compressor (PAG) oil to be used varies Insert the nut into the union. according to the compressor model. Be sure to apply First, tighten the nut by hand as much as possible, then oil specified for the model of compressor.
  • Page 79 1A–50 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Leak Check Inspection of refrigerant leak Therefore, it is most important to repair refrigerant leak when there is any leak found. Refrigerant leak may cause an adverse effect not only on the performance and durability of each component of the air-conditioner, but also on the global atmosphere.
  • Page 80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–51 3. If the leak is still present, discharge and recover the WARNING: refrigerant from the system. D SHOULD HFC-134A CONTACT YOUR EYE(S), 4. Replace the O-rings. CONSULT A DOCTOR IMMEDIATELY. D O-rings cannot be reused. Always replace with new D DO NOT RUB THE AFFECTED EYE(S).
  • Page 81 1A–52 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Recycling 8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the Recycle refrigerant recovered J-39500 gauge manifold pressure is at 750 mmHg (30 inHg), (ACR :HFC-134a Refrigerant Recovery / Recycling / close both hand valves.
  • Page 82 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–53 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle. 4. Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle.
  • Page 83 1A–54 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Checking The A/C System 1. Run the engine and close all the vehicle doors. 2. Turn A/C switch “ON”, set the fan switch to its highest position. 3. Set the air source lever to “CIRC”, set the temperature lever to the full cool position.
  • Page 84: Compressor Assembly

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–55 Compressor Assembly Compressor Assembly and Associated Parts 852RW010 Legend (3) Refrigerant Line Connector (1) Compressor Bracket (4) Compressor (2) Seal Washer (5) Drive Belt Removal 2. Discharge and recover refrigerant D Refer to Refrigerant Recovery in this section. 1.
  • Page 85: Installation

    1A–56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 4. Remove drive belt. 4. Connect magnetic clutch harness connector. D Move drive belt tensioner to loose side using wrench then remove drive belt. 850RY00001 Legend (1) Auto Tensioner (2) Idle Pulley (3) Cooling Fan Pulley (4) Drive Belt (5) Power Steering Oil Pump (6) Air Conditioner Compressor...
  • Page 86: Condenser Assembly

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–57 Condenser Assembly Condenser Assembly and Associated Parts 875RY00005 Legend (4) Radiator Grille (1) Refrigerant Line (5) Engine Hood Front End Stay (2) Pressure Switch Connector (6) Condenser Assembly (3) Front Bumper Assembly Removal Installation 1.
  • Page 87: Receiver / Drier

    1A–58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D Be sure to apply new compressor oil to the O-rings 4. Install engine hood front end stay. when connecting the refrigerant line. 5. Install front bumper assembly. 3. Connect pressure switch connector. 6.
  • Page 88: Pressure Switch

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–59 Pressure Switch Pressure Switch and Associated Parts 875RY00006 Legend (2) Pressure Switch (1) Pressure Switch Connector (3) Radiator Grille Removal Installation To install, follow the removal steps in the reverse order, 1. Disconnect the battery ground cable. noting the following point: 2.
  • Page 89: Evaporator Assembly

    1A–60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Evaporator Assembly Evaporator Assembly and Associated Parts 874RT002 Legend (5) Instrument Panel Passenger Lower Cover Assembly (1) Resistor and Electronic Thermostat Connector (6) Glove Box (2) Drain Hose (7) Front Console Assembly (3) Refrigerant Line (8) Lower Cluster Assembly (4) Passenger Knee Bolster Reinforcement (9) Evaporator Assembly...
  • Page 90: Electronic Thermostat, Evaporator Core And/Or Expansion Valve

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–61 9. Disconnect drain hose. 1. To install a new evaporator assembly, add 50cc (1.7 fl. oz.) of new compressor oil to the new core. 10. Disconnect refrigerant line. D Use a back-up wrench when disconnecting and 2.
  • Page 91: Installation

    1A–62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. Remove evaporator assembly. D Refer to Evaporator Assembly in this section. 4. Remove the electronic thermostat sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7.
  • Page 92: Air Conditioning Switch And Illumination Bulb 1A-63

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–63 6. Be sure to install the sensor and the insulator on the 8. Tighten the refrigerant lines to the specified torque. place where they were before. Refer to Main Data and Specifications for Torque Specifications in this section.
  • Page 93: Refrigerant Line

    1A–64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Line Refrigerant Line and Associated Parts 852RY00013 Legend (4) Discharge Line (High Pressure Hose) (1) Clip and Clamp (5) Air Cleaner (2) Suction Line (Low Pressure Hose) (6) Radiator Grille (3) Liquid Line (High-Pressure Pipe) (7) Suction Line (Low-Pressure Pipe) Removal 7.
  • Page 94: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–65 D When removing the refrigerant line connecting part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. Installation To install, follow the removal steps in the reverse order, noting the following points: 1.
  • Page 95: Main Data And Specifications

    1A–66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Main Data And Specifications General Specifications HEATER UNIT Temperature control Reheat air mix system Capacity 4.3 kw (3,700 Kcal./hr.) Air flow 280 m#/hr HEATER CORE Type Plate and corrugate fin type Element dimension 171 mm (6.7 in.) 161 mm (6.3 in.) 25 mm (0.98 in.)
  • Page 96 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–67 Torque Specifications 852RW004 874RX016...
  • Page 97: Compressor

    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.
  • Page 98 This PAG lubricant should then be discarded and an equal amount of new PAG lubricant added to the compressor. The service compressor is shipped without PAG oil. When service procedures require, use only Isuzu approved PAG oil.
  • Page 99: Metric Thread Size Information

    1A–70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Metric Thread Size Information Compressor to mounting bracket bolts (Front) Compressor shaft 1.5 – 6H 1.25 – 6H Compressor to mounting bracket bolts (Rear) Internal hub-clutch drive assembly 1.25 – 6H 1.5 – 6H Suction-discharge port screw 1.5 –...
  • Page 100: Compressor Clutch Rotor And/Or Bearing

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–71 installer is held and the center screw is rotated, the 7. Remove installer J-33013-B, check for proper key will wedge and will break the clutch hub. positioning of the shaft key (even or slightly above the clutch hub).
  • Page 101: Compressor Clutch Coil

    1A–72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. Position puller crossbar J-8433-1 on the puller pilot 5. Install rotor and bearing assembly retainer ring, using J-33023-A and assemble the two J-33026 through snap ring pliers . bolts and washers through the puller bar slots and 6.
  • Page 102: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–73 Installation 1. Place the clutch coil assembly (1) on the front head with the terminals positioned at the “marked” location. 2. Place the J-33024 clutch coil installer over the internal opening of the clutch coil housing and align installer with the compressor front head.
  • Page 103: Compressor Shaft Seal

    1A–74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Compressor Shaft Seal Service Precaution Seal Leak Detection When replacing the shaft seal assembly, pressure relief A shaft seal should not be changed because of small valve or control switches, it will be necessary to recover amounts of oil found on an adjacent surface but only after the refrigerant.
  • Page 104: Cleaning

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–75 7. Remove and discard the seal seat O-ring (2) from the 2. Insert O-ring installer J-33011 into compressor neck using O-ring remover J-9553-01. compressor neck until the installer “bottoms”. Lower the moveable slide of the O-ring installer to release the O-ring into the seal O-ring lower groove (The compressor neck top groove is for the shaft seal retainer ring.) Rotate the installer to seat the O-ring...
  • Page 105: Compressor Pressure Relief Valve

    1A–76 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 6. Remove any excess oil resulting from installing the 8. Reinstall compressor belt and tighten bracket. new seal parts from the shaft and inside the 9. Evacuate and charge the refrigerant system. compressor neck. 7.
  • Page 106: Contamination Of Compressor Oil

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–77 1. Perform oil return operation. (Component parts to be (Amount of Oil) 2. Discharge and recover the refrigerant and remove the installed) compressor. Evaporator 50 cc (1.7 fl. oz.) 3. Drain the compressor oil and measure the extracted Condenser 30 cc (1.0 fl.
  • Page 107 1A–78 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 14. Attach the compressor to the J-34992 holding fixture and mount the compressor in a vise so that the compressor will be in a horizontal position and the shaft can be turned with a wrench. 15.
  • Page 108: Special Tools

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–79 Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J-33013-B J-8433-3 Hub and Clutch Drive Forcing Screw Plate Asm. remover J-33026 J-33025 Compressor Holding Clutch Coil Installer Fixture Adapter J-33024 J-33023-A Clutch Coil Installer Puller Pilot...
  • Page 109 1A–80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) TOOL NO. ILLUSTRATION TOOL NAME J-34614 Shaft Seal Protector J-39893 Pressure Testing Connector...
  • Page 110: Automatic Air Conditioning System

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–81 Automatic Air Conditioning System General Description off the compressor and switch the blow port as well as switching between the fresh air intake and interior air Using a variety of sensors, this automatic heater and air circulation.
  • Page 111: Refrigerant Line And Associated Parts

    1A–82 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Line and Associated Parts 852RY00002 Legend (7) Condenser Assembly (1) Liquid Line (High Pressure Pipe) (8) Drive Belt (2) O – Ring (9) Compressor (3) Discharge Line (High Pressure Hose) (10) Drain Hose (4) Pressure Switch (11) Suction Line (Low-Pressure Hose) (5) Receiver Drier...
  • Page 112: Circuit Diagram

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–83 Circuit Diagram 6VE1 Engine D08RY00109...
  • Page 113 1A–84 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D08RY00110...
  • Page 114 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–85 D08RY00155...
  • Page 115 1A–86 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D08RY00147...
  • Page 116 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–87 D08RY00148...
  • Page 117: Functions And Features

    1A–88 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Functions and Features the system. Self-diagnosis function Automatic interior temperature control The self-diagnosis function turned on from the panel This function enables to maintain the interior switch makes your troubleshooting easier (for detail temperature at the level specified from the of this function, refer to the section titled temperature control switch despite of changes in...
  • Page 118: Automatic Air Conditioner Block Diagram

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–89 Automatic Air Conditioner Block Diagram F01RY00006...
  • Page 119: Control Panel Layout

    1A–90 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Control Panel Layout 865RY00024 Legend (5) Intake Switch (1) Auto Switch (6) Fan Switch (2) Mode Switch (7) Air Conditioning Switch (3) DEF/FOOT Switch (8) Temperature Control Knob (4) DEF Switch...
  • Page 120: Air Control Functions

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–91 Air Control Functions C01RY00004 Legend (7) FOOT Door (1) Interior Air Intake (8) Sub Air Mix Door (2) Fresh Air Intake (9) Heater Unit (10) Heater Core (3) Evaporator Core (4) Air Mix Door (11) Evaporator Unit (5) DEF Door (12) Blower Unit...
  • Page 121: Operation And Functions Of Control Panel Switches

    1A–92 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Operation and Functions of Control Panel Switches D The A/C LED remains turned on even if the Auto Switch compressor has been turned off because of the given 1. Pressing this switch turns on the automatic control outside air temperature level.
  • Page 122 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–93 F01RX005 Indication Fan Switch D The Auto LED maintains unaffected. 1. Sets the fan to the specified mode. D Currently selected intake port is indicated. 2. Even when the fan switch is turned off, status display for the Mode, Intake is maintained.
  • Page 123: Overview Of Construction, Movement And Control Of Major Parts Of Automatic Air Conditioner System

    1A–94 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Indication D As long as the MAX control is selected, the immediately preceding indication shall be maintained for the AUTO. D Status display is provided for others. Air Conditioning Switch Pressing this switch turns on or off the A/C (air conditioning) control.
  • Page 124 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–95 Duct Sensor Sun Sensor The duct sensor is the sensor to detect temperature It is a photodiode used for detecting quantity of solar change of the side of evaporator blower coming by fresh radiation.
  • Page 125 1A–96 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Max Hi Relay Actuator This relay turned on or off by the signal from the automatic The actuators are power driven type containing a small heater/air conditioner control unit. As the Max Hi relay is motor.
  • Page 126 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–97 The actuator changes the motor speed using the gear Movement of Mix Actuator and drives each door rotating the output axis united with Position of the air mix door is determined by the controller the sliding contact.
  • Page 127: Overview Of Automatic Control Of Automatic Air Conditioner

    1A–98 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Movement of Mode Actuator Movement of Intake Actuator As target position of the mode door is decided on the The controller on the automatic heater/air conditioner controller of the control unit, the control unit reads the control unit selects an intake mode to be used.
  • Page 128 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–99 Interior Temperature Control Air Flow Control The automatic heater/air conditioner control unit operates In the Auto Mode on the setup temperature signal from the temperature D The automatic heater/air conditioner control unit control switch and other sensor signals to derive the total operates on the setup temperature signal and other signal.
  • Page 129 1A–100 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Mode (Blow Port) Control Intake (Fresh air/interior air switching) Control The automatic heater/air conditioner control unit operates on the setup temperature from the control switch, and In the Full Auto mode, the automatic heater/air temperature and solar radiation quantify from the sensors conditioner control...
  • Page 130 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–101 Compressor Control In the automatic control mode, the automatic heater/air conditioner control unit turns on or off the compressor with the evaporator anti–freeze mechanism using the evaporation sensor. And, when outside air is detected to be low through the outside air temperature sensor signal, the control unit turns off the compressor using the compressor control function.
  • Page 131: Troubleshooting

    1A–102 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Troubleshooting Troubleshooting, Its Overview and When implementing troubleshooting, this self-diagnosis function narrows the range to be searched Procedures at the first step, then check relevant parts one by one according to the “Checking Procedures by Failed The full automatic heater and air conditioner equips with Location”.
  • Page 132: Auto Air Conditioner Control Unit Power Supply Diagnosis

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–103 Auto Air Conditioner Control Unit Power Supply Diagnosis This check is required because a trouble on the auto amplifier (control unit) power supply circuit or grounding circuit prevents accurate troubleshooting. D08RY00138 Condition Possible cause Correction Power source does not supply to —...
  • Page 133 1A–104 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart “A”: Check of Auto Amplifier Power Supply System Step Action Value(s) Is the fuse C–16 normal? Replace the — Go to Step 2 fuse Is the fuse C–20 normal? Replace the — Go to Step 3 fuse Disconnect the auto A/C control unit connector I–32.
  • Page 134: Performance And Movement Checklist For Automatic Air Conditioner Related Parts

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–105 Performance and Movement checklist for Automatic Air Conditioner Related Parts Start the engine, and when the engine coolant reached 122°F check performance and movement of the related parts according the following checklist. Performance Check Using the Manual Switch Checking Approach Item Item...
  • Page 135 1A–106 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Check of Auto Function Checking Approach Item Item Acceptance criteria Acceptance criteria Condition Operation The LED shall come on. Cold air shall be blown out. The following LEDs shall come on: D Blow port mode: Select FC for the D Intake mode temperature.
  • Page 136: Troubleshooting With Self-Diagnosis Function

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–107 Troubleshooting With Self-Diagnosis Function For turning on the self-diagnosis function and switching of Overview of Self-Diagnosis Function the check step, refer to the flow chart given below. You The self-diagnosis is implemented in 3 steps for each can reset the self–diagnosis function by turning the target.
  • Page 137 1A–108 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Displaying the Current Trouble one in 0.5 second interval irrespective of presence or absence of a trouble for a given item. When the display 9 Diagnosing Table items is completed, it is repeated with 3 seconds of Start the engine while holding down both the Auto switch interval in between.
  • Page 138 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–109 As shown above, display of result along nine items is past trouble diagnosis will appear on the indicator lamp repeated with 3-second interval in between. (LED) of the air conditioning switch. Note 1: When checking the sun sensor, apply sufficient Results of the diagnosis along the following five items are light using a 60W bulb.
  • Page 139 1A–110 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Check of Output Equipment F01RY00004...
  • Page 140: Inspection By Failed Location

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–111 Inspection By Failed Location Inspection of the Sensors When the self-diagnosis function has determined that trouble is present on the sensors, check them according to the following flow chart. F01RY00005...
  • Page 141 1A–112 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart 1: In Car Sensor D08RY00174 Step Action Value(s) Disconnect the in car sensor connector. (No.I-34) Is performance of the sensor normal? (Refer to the Replace the later section on “Individual Inspection”) — Go to Step 2 in car sensor Is there continuity between the harness side connector...
  • Page 142 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–113 Chart 2: Ambient Sensor D08RY00140 Step Action Value(s) Disconnect ambient sensor connector. (No.C–86) Replace the Is performance of the ambient sensor normal? (Refer ambient to the later section on “Individual inspection”) — Go to Step 2 sensor Connect the ambient sensor connector.
  • Page 143 1A–114 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart 3: Sun Sensor D08RY00139 Step Action Value(s) Disconnect the sun sensor connector. (No.I–35) Is performance of the sun sensor normal? (Refer to the Replace the later section on individual inspection) — Go to Step 2 sun sensor.
  • Page 144: Inspection Of The Intake Actuator System

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–115 Inspection of the Intake Actuator System D08RY00142...
  • Page 145 1A–116 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition Possible cause Correction Does not work at all — Refer to Chart A Control failure — Refer to Chart B Chart A: Does Not Work At All Step Action Value(s) Is the fuse FL–1 normal? Replace the —...
  • Page 146 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–117 Chart B: Failure on the Intake Control Step Action Value(s) Is the fuse No.C–20 normal? Replace the — Go to Step 2 fuse Is the relay No.B–36 normal? Replace the — Go to Step 3 relay Turn on the ignition switch.
  • Page 147: Inspection Of The Mix Actuator System

    1A–118 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Inspection of the Mix Actuator System D08RY00145 Condition Possible cause Correction Does not work at all — Refer to Chart A Control failure — Refer to Chart B...
  • Page 148 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–119 Chart A: Does Not work At All Step Action Value(s) 1. Turn on the ignition switch (the engine is run). 2. Disconnect the mix actuator connector (I–45). 3. Short-circuit the chassis harness side connector terminal No.I45–3 and No.I45–7.
  • Page 149 1A–120 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart B: Mix Actuator Control Failure Step Action Value(s) Turn the ignition switch (the engine is run). Dose the mix actuator fully stroke when FH and FC of the temperature control lever? — Go to Step 3 Go to Step 2 Repair or replace the air mix door or the link unit.
  • Page 150: Inspection Of The Mode Actuator System

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–121 Inspection of the Mode Actuator System D08RY00146 Condition Possible cause Correction Does not work at all — Refer to Chart A Control failure — Refer to Chart B...
  • Page 151 1A–122 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart A: Does Not Work At All Step Action Value(s) 1. Turn on the ignition switch (the engine is run). 2. Disconnect the mode actuator connector (B–69) 3. Select VENT pressing the mode actuator. Is the battery voltage provided on a regular interval between the harness side connector terminal No.B69–1 (+) and No.B69–5 (-)?
  • Page 152 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–123 Chart B: Mode Actuator Control Failure Step Action Value(s) Turn on the ignition switch (the engine is run). Dose the mode actuator fully stroke when the defrost mode and the vent mode are selected? —...
  • Page 153: Inspection Of The Fan Motor System

    1A–124 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Inspection of the Fan Motor System D08RY00144...
  • Page 154 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–125 Condition Possible cause Correction The fan dose not rotate at all — Refer to Chart A The fan dose not rotate in the — Refer to Chart B MAX–HI mode The fan dose not rotate in any mode —...
  • Page 155 1A–126 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart B: Fan Does Not Rotate in MAX HI Mode Step Action Value(s) Is the MAX-HI relay (I–51) normal? Replace the — Go to Step 2 relay 1. Turn on the ignition switch (the engine is run). 2.
  • Page 156 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–127 Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI Step Action Value(s) Is the power transistor performance normal? (Refer to Replace the the later section on “individual inspection”) power —...
  • Page 157 1A–128 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart D: Fan Does Not Stop Step Action Value(s) 1. Disconnect the max high relay, the power transistor connector I–50 and the auto A/C control unit connector I–33. 2. Turn on the ignition switch. Does the blower motor stop? —...
  • Page 158: Inspection Of The Magnetic Clutch System 1A-129

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–129 Inspection of the Magnetic Clutch System 6VE1 Engine D08RY00143...
  • Page 159 1A–130 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition Possible cause Correction Magnetic clutch does not work — Refer to Chart A Chart A: Magnetic Clutch Does Not work Step Action Value(s) Is the fuse No.C–20 normal? Replace the — Go to Step 2 fuse Is the relay No.X–7 (compressor relay) No.X–5 (A/C Replace the...
  • Page 160 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–131 Chart A: Magnetic Clutch Does Not work (Cont’d) Step Action Value(s) Repair an open circuit between terminal No.X5–1 and I32–14. Is the action complete? — Go to Step 17 — Is there continuity between the harness side connector —...
  • Page 161: Individual Inspection

    1A–132 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Individual Inspection Sun Sensor 1. Disconnect the sun sensor connector (I–35). In Car Sensor 2. Measure the current value on the sun sensor when 1. Disconnect the in car sensor connector (I–34). placed it approximately 15 cm away from 60W 2.
  • Page 162 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–133 Power Transistor In Car Sensor 1. Remove the power transistor connector (I–50) from 1. Turn on the ignition switch (the engine is started). the evaporator assembly. Start the air conditioner in “Full Auto”. 2.
  • Page 163 1A–134 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater (B–36), Thermostat (X–5), And Compressor (X–7) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. D For handling of these relays, refer to Heater Relay in this section. 901RY00041 Triple Pressure Switch (V6, A/T) 1.
  • Page 164: On-Vehicle Service

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–135 On-Vehicle Service Power Transistor Automatic Heater/Air Conditioner Control Unit 874RY00010 Legend 865RY00012 (1) Evaporator Assembly Legend (2) Power Transistor (1) Connector (3) Power Transistor Connector (2) Set Screw (4) Instrument Panel Passenger Lower Cover (3) Instrument Panel Cluster (5) Glove Box (4) Automatic Heater/Air Conditioner Control Unit...
  • Page 165: In Car Sensor

    1A–136 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) In Car Sensor Ambient Sensor 865RY00020 875RY00001 Legend Legend (1) In Car Sensor (1) Ambient Sensor (2) Automatic Heater/Air Conditioner Control Unit (2) Sensor Connector (3) Radiator Grille Removal Removal 1. Disconnect the battery ground cable. 1.
  • Page 166: Sun Sensor

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–137 Sun Sensor Electronic Thermostat 826RY00012 Legend (1) Sun Sensor Removal 1. Disconnect the battery ground cable. 2. Remove the sun sensor. 3. Disconnect the sun sensor connector. 874RX022 Legend Installation (1) Duct Sensor To install, follow the removal step in the reverse order.
  • Page 167: Mode Actuator

    1A–138 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Mode Actuator Mix Actuator 860RY00008 860RY00009 Legend Legend (1) A/T Control Unit (1) Instrument Panel Assembly (2) Actuator Rod (2) Actuator Rod (3) Mode Actuator (3) Mix Actuator (4) Instrument Panel Center Bracket Removal Removal 1.
  • Page 168 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–139 Intake Actuator 873RY00004 Legend (1) Evaporator Assembly (2) Intake Actuator (3) Intake Actuator Connector Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3.
  • Page 169: Power Assisted System

    SECTION POWER ASSISTED SYSTEM 2A–1 TROOPER STEERING POWER ASSISTED SYSTEM CONTENTS Service Precaution ..... . 2A–2 Installation ......2A–38 General Description .
  • Page 170: Service Precaution

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...
  • Page 171 POWER ASSISTED SYSTEM 2A–3 Hydraulic Pump 442RV006 The hydraulic pump is a vane-type design. There are two Pressure Switch openings at the rear of the pump housing. The larger When hydraulic pressure reaches 3650 350 kPa (530 opening contains the cam ring, pressure plate, thrust 50 psi), the pressure switch of the power steering pump plate, rotor and vane assembly, and end plate.
  • Page 172 POWER ASSISTED SYSTEM 2A–4 Steering Linkage 433RS007 Legend (4) Relay Lever (1) Center Track Rod Assembly (5) Rod End,Outer (2) Outer Track Rod Assembly (6) Track Rod (3) Pitman Arm (7) Rod End,Inner The steering linkage consists of a pitman arm, relay lever, center track rod, and two adjustable outer track rods.
  • Page 173: Diagnosis

    POWER ASSISTED SYSTEM 2A–5 Steering Column 3. With the column mounted lock, the ignition and steering operation can be locked to prevent theft of WARNING: TO AVOID DEPLOYMENT WHEN the vehicle. TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT The column can be disassembled and reassembled. USE ELECTRICAL TEST EQUIPMENT, SUCH AS However, to ensure the energy absorbing action, use only BATTERY-POWERED...
  • Page 174 POWER ASSISTED SYSTEM 2A–6 Condition Possible cause Correction Shimmy, Shake or Vibration Tire or wheel out of balance. Balance wheels or replace tire/or wheel. Loose wheel bearings. Replace wheel bearing. Worn steering linkage ball joints. Replace ball joints. Worn upper or lower ball joints. Replace ball joints Excessive wheel runout.
  • Page 175 POWER ASSISTED SYSTEM 2A–7 Condition Possible cause Correction Abnormal Noise Worn, sticky or loose upper or lower Replace. ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Replace. Worn upper or lower control arm Replace. bushing. Loose stabilizer bar.
  • Page 176 POWER ASSISTED SYSTEM 2A–8 Power Steering System There is some noise in all power steering systems. One tween this noise and steering performance. Do not re- of the most common is a hissing sound when the steering place the valve unless the “hissing” noise is extremely ob- wheel is fully turned and the car is not moving.
  • Page 177 POWER ASSISTED SYSTEM 2A–9 Power Steering Pump Foaming milky power steering fluid, low fluid level, and is low. If the fluid level is correct and the pump still foams, possible low pressure can be caused by air in the fluid, or remove the pump from the vehicle and check the housing loss of fluid due to internal pump leakage.
  • Page 178 2A–10 POWER ASSISTED SYSTEM Turn Signal Switch This diagnosis covers mechanical problems only. Refer to Turn Signal Switch in Electrical section for electrical diagnosis. Condition Possible cause Correction Turn Signal Will Not Stay In Turn Foreign material or loose parts Repair or replace signal switch.
  • Page 179: Power Steering System Test

    POWER ASSISTED SYSTEM 2A–11 Power Steering System Test Test Procedure F02RX001 Legend (3) To Power Steering Gear (1) Bolt (M16 1.5) (4) To Power Steering Pump (2) Hose (Vehicle Side) Test of fluid pressure in the power steering system is 4.
  • Page 180: Maintenance

    2A–12 POWER ASSISTED SYSTEM 7. If the pump pressures are within specifications, leave Bleeding The Power Steering System the valve open and turn (or have someone else turn) When a power steering pump or gear has been installed, the steering wheel fully in both directions. Record the or an oil line has been disconnected, the air that has highest pressures and compare with the maximum entered the system must be bled out before the vehicle is...
  • Page 181: Steering Wheel Free Play Adjustment

    POWER ASSISTED SYSTEM 2A–13 4. Install all the lines and hoses. Fill the system with new Adjustment power steering fluid and bleed the system as described in Bleeding The Power Steering System. Operate the engine for about 15 minutes. Remove the pump return line at the pump inlet and plug the connection on the pump.
  • Page 182 2A–14 POWER ASSISTED SYSTEM Camber: Caster(1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the This illustration is viewed from the front of the vehicle. vehicle). A backward tilt is positive(+) and a forward tilt is negative (–).
  • Page 183 POWER ASSISTED SYSTEM 2A–15 6. Inspect the wheels and tires for run-out. Refer to 1. Check and adjust the tire inflation pressures. Wheel Replacement in Wheel and Tire System 2. Park the vehicle on a level ground and move the front section.
  • Page 184 2A–16 POWER ASSISTED SYSTEM Tighten the fulcrum pin bolt to the specified torque. Torque: 152 N·m (112 lb ft) Camber Adjustment The camber angle can be adjusted by means of the camber shims(2) installed in position between the chassis frame(1) and fulcrum pins Camber angle: 0°...
  • Page 185 POWER ASSISTED SYSTEM 2A–17 Toe-in Adjustment 3. Adjust the inside wheel angle of each side with the stop bolts. 1. To adjust the toe-in angle, loosen the lock nuts(2) on NOTE: The maximum protruding length(1) of stop bolt(3) the outer track rods(1) and turn the outer track rods. from the lock nut(2) should be 10 mm or less Turn both rods the same amount, to keep the steering wheel centered .
  • Page 186: Main Data And Specifications

    2A–18 POWER ASSISTED SYSTEM Main Data and Specifications General Specification Caster 2°10’ 45’ Camber 0° 30’ King pin inclination 12°30’ 30’ Toe-in 2 mm (0 0.08 in) Max. steering angle inside 34° (+0° to –2°) outside 32° Torque Specification E03RS001...
  • Page 187: Special Tools

    POWER ASSISTED SYSTEM 2A–19 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–29877–A Tester: Power steering J–39213 Adapter: Power steering tester J–29107 Remover: Pitman arm J–26508 Installer: Extension housing oil seal...
  • Page 188: Power Steering Gear

    2A–20 POWER ASSISTED SYSTEM Power Steering Gear Power Steering Gear and Associated Parts 431RS002 Legend (4) Nut (1) Pipe (5) Gear Box Mounting Bolt and Nut (2) Universal Joint Bolt (6) Gear Box (3) Pitman Arm Removal 1. Remove the stone guard. 2.
  • Page 189: Installation

    POWER ASSISTED SYSTEM 2A–21 7. Make a setting mark(1) across the coupling flange and worm shaft to ensure reassembly of the parts in the original position, then remove universal joint bolt. 431RW004 2. Tighten gear box mounting bolt and nut to specified torque.
  • Page 190: Steering Gear Disassembled View

    2A–22 POWER ASSISTED SYSTEM Steering Gear Disassembled View 440RS001 Legend (7) Seal Ring (1) Dust Cover (8) O-ring (2) Retaining Ring (9) Gear Box (3) Back Up Ring (10) Sector Shaft (4) Oil Seal (11) Top Cover Assembly (5) Ball-nut and Valve Housing Assembly (12) Lock Nut (6) O-ring...
  • Page 191: Disassembly

    POWER ASSISTED SYSTEM 2A–23 Disassembly 6. Remove the top cover bolts and the top cover assembly. CAUTION: Do not clamp the steering gear assembly in a vise by the power cylinder housing. 1. Remove dust cover. 2. Remove retaining ring. 3.
  • Page 192: Inspection And Repair

    2A–24 POWER ASSISTED SYSTEM 8. Remove ball-nut and valve housing assembly. Ball-nut Rotation 440RS005 440RS006 D Always keep the ball nut and valve housing Hold the ball nut and valve housing assembly vertically assembly in a horizontal position to prevent them and see if the ball-nut lowers by turning smoothly.
  • Page 193: Reassembly

    POWER ASSISTED SYSTEM 2A–25 Dust Seal and Seal Ring Setting 3. Apply a thin coat of power steering fluid to the new seal ring(1) and be sure to discard used part, then install seal ring. 4. Apply a thin coat of power steering fluid to the new O-ring and be sure to discard used part, then install o-ring.
  • Page 194 2A–26 POWER ASSISTED SYSTEM D Lock the sector shaft adjusting screw with the lock 6. Install sector shaft. D Tape the sector shaft serrations to protect the seal nut. ring from damage. Lock nut torque: 41 N·m (30 lb ft) D Align the center tooth of ball nut with that of the 10.
  • Page 195: Main Data And Specifications

    POWER ASSISTED SYSTEM 2A–27 Main Data and Specifications General Specifications Steering unit Type Integral, ball screw Gear ratio 16.3 : 1 Torque Specifications E03RS003...
  • Page 196: Power Steering Pump

    2A–28 POWER ASSISTED SYSTEM Power Steering Pump Power Steering Pump and Associated Parts 436RW003 Legend (4) Belt (1) Hose, Suction (5) Pulley (2) Hose, Flexible (6) Pump Assembly (3) Bolt Removal 1. Drain the engine coolant. 2. Place a drain pan below the pump. 3.
  • Page 197: Installation

    POWER ASSISTED SYSTEM 2A–29 4. Remove the drive belt. 5. Remove the pulley from the power steering pump. 6. Disconnect the suction hose. 7. Disconnect the flexible hose. 8. Remove the power steering pump fixing bolt. 9. Remove the pump assembly. CAUTION: When removing the prmp assembly, be careful not to damage the wiring harnessunder the pump housing.
  • Page 198: Power Steering Pump Disassembled View 2A-30

    2A–30 POWER ASSISTED SYSTEM Power Steering Pump Disassembled View 412RX005 Legend (14) Rear Housing Assembly and Pump Cartridge (1) Bolt (15) Side Plate (2) Suction Pipe (16) Rotor and Vane (3) O-ring (17) Pin (4) Front Housing (18) Cam (5) Snap Ring (19) Rear Housing (6) Shaft Assembly (20) Bolt...
  • Page 199: Inspection And Repair

    POWER ASSISTED SYSTEM 2A–31 15. Remove the bolt. Vane 16. Remove the rear housing assembly and the pump cartridge. 17. Remove the gasket. 18. Remove the O-ring. 19. Remove the O-ring. 20. Remove the front housing. 21. Remove the side plate. 22.
  • Page 200: Reassembly

    2A–32 POWER ASSISTED SYSTEM steering fully to the left; engine idle will increase. If system 9. Install a new o-ring and be sure to discard used parts. fails to function properly, disconnect connector at the 10. Install a new gasket and be sure to discard used pressure switch and repeat system check while testing parts.
  • Page 201: Main Data And Specifications

    POWER ASSISTED SYSTEM 2A–33 Main Data and Specifications General Specifications Oil pump Type Vane Operating ATF DEXRON –III fluid Torque Specifications E02RX005...
  • Page 202: Center Track Rod Assembly

    2A–34 POWER ASSISTED SYSTEM Center Track Rod Assembly Center Track Rod Assembly and Associated Parts 433RW001 Legend (3) Nut and Cotter Pin, Relay Lever (1) Nut and Cotter Pin (4) Center Track Rod Assembly (2) Nut and Cotter Pin, Pitman Arm...
  • Page 203: Removal

    POWER ASSISTED SYSTEM 2A–35 Removal 4. Remove nut and cotter pin then use remover J–36831 to remove relay lever from the center track rod. 1. Raise the vehicle and support the frame with suitable CAUTION: Be careful not to damage the ball joint safety stands.
  • Page 204: Outer Track Rod Assembly

    2A–36 POWER ASSISTED SYSTEM Outer Track Rod Assembly Outer Track Rod Assembly and Associated Parts 433RS012 Legend (4) Rod End Assembly, Outer (1) Rod End Assembly, Inner (5) Nut and Cotter Pin, Knuckle Arm (2) Lock Nut, Inner (Left-hand threads) (6) Nut and Cotter Pin, Center Track Rod (3) Lock Nut, Outer...
  • Page 205: Removal

    POWER ASSISTED SYSTEM 2A–37 Removal 5. Apply setting marks (1) to ensure reassembly of the parts in their original position, then remove outer rod 1. Remove wheel and tire assembly. Refer to Wheel end assembly. Replacement in Suspension section. 2. Remove nut and cotter pin, then use remover J–36831 to disconnect outer track rod assembly at the center track rod.
  • Page 206 2A–38 POWER ASSISTED SYSTEM Installation 1. Install inner rod end and align the setting marks applied during disassembly. 2. Tighten the inner lock nut to specified torque. Torque: 118 N·m (87 lb ft) NOTE: For either outer rod, the screw on the right side of the vehicle is threaded counterclockwise.
  • Page 207: Relay Lever

    POWER ASSISTED SYSTEM 2A–39 Relay Lever Relay Lever and Associated Parts 433RS017 Legend (4) Relay Lever (1) Bolt and Nut (5) Nut and Washer (2) Relay Lever and Bracket (6) Nut and Cotter Pin (3) Bracket Removal 1. Raise the vehicle and support the frame with suitable safety stands.
  • Page 208: Installation

    2A–40 POWER ASSISTED SYSTEM 3. Remove stabilizer bar bolt and nut and push the Installation stabilizer bar aside, then remove the relay lever bolts 1. Install bracket. and nuts. 2. Install relay lever. 3. Install nut and washer and tighten the nut to the specified torque.
  • Page 209: Steering Linkage And Associated Parts

    POWER ASSISTED SYSTEM 2A–41 Steering Linkage and Associated Parts Main Data and Specifications Torque Specifications E03RS004...
  • Page 210: Special Tools

    2A–42 POWER ASSISTED SYSTEM Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–36831 Tie rod end remover J–22912–01 Relay lever remover...
  • Page 211: Supplemental Restraint System Steering Wheel & Column

    POWER ASSISTED SYSTEM 2A–43 Supplemental Restraint System Steering Wheel & Column Service Precaution TO AVOID DEPLOYMENT WHEN TROUBLE SHOOT- ING THE SRS SYSTEM, DO NOT USE ELECTRICAL This steering wheel and column repair section covers the TEST EQUIPMENT, SUCH AS BATTERY-POWERED Supplemental Restraint System (SRS) steering column.
  • Page 212 2A–44 POWER ASSISTED SYSTEM Removal Installation To remove the connector, hold the cover insulator(1) and To install the connector, hold the soket insulator(1) and pull it. The cover insulator slides and lock will be released. insert it. The cover insulator slides and connector will be Do not hold the socket insulator(2).
  • Page 213: Inflator Module

    POWER ASSISTED SYSTEM 2A–45 Inflator Module Inflator Module and Associated Parts 827RS048 Legend (2) Inflator Module (1) Module Connector (3) Fixing Bolt Removal 1. Turn the steering wheel so that the vehicle’s wheels are pointing straight ahead. 2. Turn the ignition switch to “LOCK”. 3.
  • Page 214: Inspection And Repair

    2A–46 POWER ASSISTED SYSTEM D Check for defects such as damage and breakage in 6. Disconnect the yellow 2-way SRS connector located behind the inflator module. the lead wire for the igniter. If an abnormality is found as the result of the inspection, replace the inflator module with a new one.
  • Page 215: Steering Wheel

    POWER ASSISTED SYSTEM 2A–47 Steering Wheel Steering Wheel and Associated Parts 827RT022 Legend (3) Inflator Module (1) Horn Lead (4) Steering Wheel (2) Steering Wheel Fixing Nut CAUTION: Once the steering column is removed Removal from the vehicle, the column is extremely 1.
  • Page 216 2A–48 POWER ASSISTED SYSTEM 5. Loosen the inflator module fixing bolt from behind the 9. Apply a setting mark (1) across the steering wheel steering wheel assembly using a TORX driver or and shaft so parts can be reassembled in their original equivalent until the inflator module can be released position, then remove steering wheel.
  • Page 217: Installation

    POWER ASSISTED SYSTEM 2A–49 Installation 7. Turn the ignition switch to “ON” while watching warning light. Light should flash 7 times and then go 1. Install steering wheel by aligning the setting marks off. If lamp does not operate correctly, refer to made when removing.
  • Page 218: Combination Switch

    2A–50 POWER ASSISTED SYSTEM Combination Switch Combination Switch and Associated Parts 431RW001 Legend (4) Combination Switch and SRS Coil Assembly (1) Steering Column Cover (5) Front Console Assembly (2) Steering Wheel (6) Steering Lower Cover (3) Inflator Module (7) Lower Cluster Assembly Removal CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the...
  • Page 219 POWER ASSISTED SYSTEM 2A–51 8. 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. Disconnect the yellow 2-way SRS connector located behind the inflator module, then remove inflator module.
  • Page 220: Installation

    2A–52 POWER ASSISTED SYSTEM CAUTION: When turning coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil. 430RT009 10. Remove steering column cover. 11. Disconnect the wiring harness connectors located under the steering column, then remove combination switch and SRS coil assembly.
  • Page 221 POWER ASSISTED SYSTEM 2A–53 4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 N·m (25 lb ft) 5. Support the inflator module and carefully connect the module connector. CAUTION: D Never use the air bag assembly from another vehicle.
  • Page 222: Lock Cylinder

    2A–54 POWER ASSISTED SYSTEM Lock Cylinder Lock Cylinder and Associated Parts 431RW003 Legend (6) Cushion Rubber (1) Inflator Module (7) Lock Cylinder Assembly (2) Steering Wheel (8) Front Console Assembly (3) Steering Column Cover (9) Lower Cluster Assembly (4) Combination Switch and SRS Coil Assembly (10) Steering Lower Cover (5) Snap Ring (11) Shift Lock Cable (for A/T)
  • Page 223 POWER ASSISTED SYSTEM 2A–55 8. Loosen the inflator module fixing bolt from behind the 10. Apply a setting mark (1) across the steering wheel steering wheel assembly using a TORX driver or and shaft so parts can be reassembled in their original equivalent until the inflator module can be released position.
  • Page 224: Installation

    2A–56 POWER ASSISTED SYSTEM WARNING: THE INFLATOR MODULE SHOULD 15. Remove snap ring. ALWAYS BE CARRIED WITH THE URETHANE 16. Remove cushion rubber. COVER AWAY FROM YOUR BODY AND SHOULD 17. Remove shift lock cable (for A/T). ALWAYS BE LAID ON A FLAT SURFACE WITH THE 18.
  • Page 225: System Inspection

    POWER ASSISTED SYSTEM 2A–57 7. When installing the steering column cover, be sure to 12. Tighten fixing bolts to specified sequence as route each wire harness as illustrated so that the illustrated. harnesses do not catch on any moving parts. Torque: 8 N·m (69 lb in) 825RW017 827RW003...