1998 ISUZU TROOPER heater

INDUCTION 6J – 11
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and remove water hose from
thermostat housing
2. Remove intercooler assembly.
3. Remove bracket fixing bolt of oil level gauge guide
tube.
4. Remove PCV hose.
5. Remove hoses from EGR valve, EGR vacuum
sensor and outlet of heater unit.
6. Disconnect harness connector from MAP sensor,
EGR vacuum sensor, ETC sensor, Water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove two way check valve.
9. Remove fuel pipe.
10. Remove fixing bolts and nuts of intake manifold,
remove intake manifold assembly.
Legend
(1) Intake manifold
(2) Fixing portion of throttle valve
(3) EGR passage
(4) EGR valve
For Europe
2
1
3
3 1 42
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket
025R200005
3124
025RW031

6J – 12 INDUCTION
INSPECTION AND RAPAIR
1. Visually check for cracks/clogs inside intake
manifold.
2. If foreign material is observed, it should be taken
out, and if there are some cracks on the intake
manifold, it must be replaced.
INSTALLATION
1. Install the intake manifold assembly, tighten bolts
and to the specified torque.
Torque: 20 N·m (2.0 kg·m / 14.5 lb ft) for bolt
Torque: 20 N·m (2.0 kg·m / 14.5 lb ft) for nut
2. Install fuel pipe.
Torque: 4 N·m (0.4 kg·m / 2.9 lb ft) for M16 nut
(Apply engine oil)
Torque: 13 N·m (1.3 kg·m / 9.4 lb ft) for M10 cap nut
Torque: 14 N·m (1.4 kg·m / 10 lb ft) for M10
(Apply engine oil)
3. Install two way check valve.
Torque: 20 N·m (2.0 kg·m / 14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
5. Install high pressure oil pipe, then tighten sleeve nut
to the specified torque.
Torque: 29 N·m (3.0 kg·m / 21.7 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water thermo unit,
IAT sensor and EVRV sensor.
7. Install hoses to EGR valve, EGR vacuum sensor
and Water outlet of heater.
8. Connect PCV hose.
9. Install oil level gauge guide and fix it.
10. Install intercooler assembly.
Refer to “Intercooler” in this manual.
11. Install water hose to thermostat housing and fill with
engine coolant.
Model of Turbocharger IHI RHF5
Turbine Maximum Speed 180,000 rpm
Maximum Inlet Gas Temperature 800 °C (1472 °F)
Vibration Peak (G) criteria Maximum 4 (G) at Turbine Rotor Speed 140,000 rpm
Tolerance Limit of Compressor Blade Height Less then 0.5 mm (0.0197 in)
MAIN DATA AND SPECIFICATIONS

8A–2LIGHTING SYSTEM
Vanity Mirror Illumination Bulb 8A–16 . . . . . . . . . . . . .
Removal 8A–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–16 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Switch 8A–17 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting Switch (Combination Switch) 8A–18 . . . . . .
Removal 8A–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Switch 8A–19 . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–19 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Switch (W/O Cruise Control) 8A–20 . . . . . .
Removal 8A–20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Switch (W/Cruise Control) 8A–21 . . . . . . . . . .
Removal 8A–21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–21 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Switch (Combination Switch) 8A–21 . . .
Removal and Installation 8A–21 . . . . . . . . . . . . . . .
Hazard Warning Switch 8A–22 . . . . . . . . . . . . . . . . . .
Removal 8A–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 8A–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Switch 8A–23 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–23 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Switch 8A–23 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–23 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Defogger Switch 8A–24 . . . . . . . . . . . . . . . . . . .
Removal 8A–24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–24 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Heater Switch 8A–25 . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Remind Switch (Starter Switch) 8A–25 . . . . . . .
Removal and Installation 8A–25 . . . . . . . . . . . . . . .
Illumination Controller 8A–26 . . . . . . . . . . . . . . . . . . . .
Removal 8A–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–26 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power/Winter Switch 8A–27 . . . . . . . . . . . . . . . . . . . . .
Removal 8A–27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–27 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 8A–28 . . . . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

LIGHTING SYSTEM8A–25
Seat Heater Switch
Removal
1. Disconnect the battery ground cable.
2. Remove four fixing screws and disconnect the switch
connectors to remove the front console assembly(4).
3. Push the lock from the back side of the front console
assembly to remove the seat heater switch(5).
825RW025
Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Push the switch with your fingers until it locks
securely.
Key Remind Switch (Starter Switch)
Removal and Installation
Refer to the removal and installation on steps of the
Starter Switch in this section.

8A–30LIGHTING SYSTEM
Power drive1.4w1Meter
Winter drive1.4w1Meter
Air bag2w1Meter
Engine warming SW0.84w1
FRT fog light SW0.84w1
RR fog light SW0.84w1
Glove box1.2w1
Ashtray1.4w1
Illumination controller0.7w1
Heater bezel150mA2
Hazard warning light SW0.84w1
Meter3.4w4Meter ASM
IlluminationCigar lighter1.4w1Light
Rear wiper & washer SW0.84w1
Rear defogger SW0.84w1
Mirror control SW45mA1
Mirror defogger SW0.7w1
Mirror folding SW0.7w1
A/T select lever1.2w1
Power & Winter SW50mA2
Cruise control main SW0.84w1
Headlight wiper SW0.84w1
Torque Specifications
ApplicationN·mkg·mLb FtLb In
Steering Shaft Nut343.525—

8DÐ2 WIRING SYSTEM
General Description . . . . . . . . . . . . . . . . . . 8DÐ272
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ273
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ275
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ279
AntiÐLock Brake System (ABS) . . . . . . . . . . 8DÐ284
General Description . . . . . . . . . . . . . . . . . . 8DÐ284
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ285
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ291
A/T Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ298
General Description . . . . . . . . . . . . . . . . . . 8DÐ298
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ299
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ300
Windshield Wiper/Washer . . . . . . . . . . . . . . 8DÐ303
General Description . . . . . . . . . . . . . . . . . . 8DÐ303
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ304
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ305
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ308
Rear Wiper/Washer . . . . . . . . . . . . . . . . . . . . 8DÐ316
General Description . . . . . . . . . . . . . . . . . . 8DÐ316
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ317
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ319
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ323
Headlight Wiper/Washer . . . . . . . . . . . . . . . 8DÐ329
General Description . . . . . . . . . . . . . . . . . . 8DÐ329
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ330
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ332
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ336
Rear Defogger . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ342
General Description . . . . . . . . . . . . . . . . . . 8DÐ342
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ343
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ344
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ347
Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ350
General Description . . . . . . . . . . . . . . . . . . 8DÐ350
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ351
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ355
Cigarette Lighter and Digital Clock . . . . . . . 8DÐ359
General Description . . . . . . . . . . . . . . . . . . 8DÐ359
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ360
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ361
Power Door Mirror . . . . . . . . . . . . . . . . . . . . 8DÐ364
General Description . . . . . . . . . . . . . . . . . . 8DÐ364
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ365
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ368
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ373
AntiÐTheft System with Keyless Entry . . . . 8DÐ380
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ381
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ392
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ399Meter and Warning/Indicator Light . . . . . . 8DÐ410
General Description . . . . . . . . . . . . . . . . . . 8DÐ410
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ411
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ429
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ445
A/T Shift Indicator . . . . . . . . . . . . . . . . . . . . . 8DÐ464
General Description . . . . . . . . . . . . . . . . . . 8DÐ464
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ465
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ467
Heater and Air Conditioning . . . . . . . . . . . . 8DÐ471
General Description . . . . . . . . . . . . . . . . . . 8DÐ471
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ472
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ474
Sun Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ484
General Description . . . . . . . . . . . . . . . . . . 8DÐ484
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ485
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ486
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ489
Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ493
General Description . . . . . . . . . . . . . . . . . . 8DÐ493
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ494
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ495
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ498
Power Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ500
General Description . . . . . . . . . . . . . . . . . . 8DÐ500
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ501
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ503
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ507
Shift on the Fly System . . . . . . . . . . . . . . . . 8DÐ513
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ514
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ516
Torque on Demand (TOD) . . . . . . . . . . . . . . 8DÐ538
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ539
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ542
Supplemental Restraint System (SRS)Ð
AIR BAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ543
General Description . . . . . . . . . . . . . . . . . . 8DÐ543
Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . 8DÐ544
Parts Location . . . . . . . . . . . . . . . . . . . . . . . 8DÐ548
Connector List . . . . . . . . . . . . . . . . . . . . . . . . 8DÐ550

8DÐ26 WIRING SYSTEM
Fuse Box
This illustration is based on RHD
C/B-1 C/B-2
C-10
C-20C-9 C-8 C-7 C-6 C-5 C-4 C-3 C-2 C-1
C-19 C-18 C-17 C-16 C-15 C-14 C-13 C-12 C-11
C-21 C-22 C-23 C-24
FUSE BOX
RHDNo.
C-1
C-2
C-3
C-4
C-5
C-6
C-7
C-8
C-9
C-10
C-11
C-12
C-13
C-14
C-15
C-16
C-17
C-18
C-19
C-20
C-21
C-22
C-23
C-24LHD
10A STARTER RELAY
15A SEAT HEATER
10A TURN, BACK
10A ELEC. IGN.
15A FRT WIPER AND WASHER
10A RR WIPER AND WASHER
10A H/LAMP WIPER
15A ENGINE
15A IGN. COIL (GASOLINE)
15A FUEL CUT (4JG2)
10A METER, GAUGE
10A AUDIO, MIRROR
20A CIGARETTE
10A ANTI-THEFT
15A STOP, A/T CONT.
20A TELEPHONE
10A CLOCK, ROOM
25A RR DEFOG.
20A DOOR LOCK
25A BLOWER
10A AIR CON.
10A SRS-110A STARTER RELAY
15A SEAT HEATER
10A TURN, BACK
10A ELEC. IGN.
15A FRT WIPER AND WASHER
10A RR WIPER AND WASHER
10A H/LAMP WIPER
15A ENGINE
15A IGN. COIL (GASOLINE)
15A FUEL CUT (4JG2)
10A METER, GAUGE
10A AUDIO, MIRROR
20A CIGARETTE
10A ANTI-THEFT
15A STOP, A/T CONT.
20A TELEPHONE
10A CLOCK, ROOM
25A RR DEFOG.
20A DOOR LOCK
25A BLOWER
10A AIR CON.
10A SRS-1 FUSE
RHDNo.
C/B-1
C/B-2LHD
30A P/W, P/S, S/R 30A P/W, P/S, S/R—— CIRCUIT BREAKER
—
—
——
—
—
810RV026

8DÐ28 WIRING SYSTEM
Relay Location-2 (Fuse Box)
1234
5
810RW330
Legend
(1) Heater & A/C Relay
(2) Power Window Relay
(3) H-63(4) Flasher Unit
(5) Rear Defogger Relay