1998 ISUZU TROOPER removing engine

2A – 86 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
INSTALLATION
11. Steering column assembly
Align the setting marks on the universal joint and
steering shaft made during removal.
Tighten the steering column fixing bolt (dash panel)
to the specified torque.
Steering Column Bolt Torque N·m (kg·m/lb·ft)
19 (1.9 / 14)
Tighten the steering column fixing bolt ( pedal
bracket) to the specified torque.
Steering Column Bolt Torque N·m (kg·m/lb·ft)
17 (1.7 / 13)
Tighten the universal joint to the specified torque.
Universal Joint Torque N·m (kg·m/lb·ft)
25 (2.5 / 18)
10. Lock cylinder assembly
9. Shift lock cable (for A/T)
8. Cushion rubber
7. Snap ring
6. Combination switch
After installation of combination switch assembly,
connect the combination switch wiring harness
connector.
5. Steering column cover
4. Steering wheel
Align the setting marks made when removing.
CAUTION:
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.
Tighten the steering wheel fixing nut to the specified
torque.
Steering wheel Nut Torque N·m (kg·m/lb·ft)
34 (3.5 / 25)
3. Steering lower cover
Install the engine hood opening lever.
2. Lower cluster assembly
1. Front console assembly
Connect the wiring harness connectors.
Install the transmission (for M/T) and transfer control

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±26
Checking Failed TOD Control Unit Pin
NOTE:
1. Unplug the ECU connector and the pins, unless
otherwise specified.2. Before removing the ECU, turn off the ignition switch.
3. If the standard values are not observed, check the
pins with other testers.
Check
Pin
No.Circuit to be
testedIgnition
Switch
PositionEngine
StateMultimeter
Scale/
RangeMeasure
between Pin
NumberStandard ValveNote
14D-G MAPOFFSTOP
14, 19Continuity : OK
(Gasoline)
20P-GNDOFFSTOP
20, 19Continuity : OK
19GNDOFFSTOP
19, GNDContinuity : OK
84H SWOFFSTOP
8, 19No continuity (high,
4L) and continuity
(N) : OK
94L SWOFFSTOP
9, 19No continuity (high)
and continuity (4L,
N) : OK
10AXLE SWONRUN
10, 19Continuity : OKRemove ECU and start the engine. Move
the vehicle forth and back to connect axle
surely.
13DIAGOFFSTOP
13 (TOD), 8
(DLC Con-
nector)Continuity : OKDLC connector terminal 8
25IND.aONSTOPDCV25 (+), 19 (±)8.0 ~14.5 VLighting SW ON : 0V
Lighting SW OFF : 8.0 ~14.5 V
26IND.bONSTOPDCV26 (+), 19 (±)8.0 ~14.5 V
27IND.cONSTOPDCV27 (+), 19 (±)8.0 ~14.5 V
30CHECK
LAMPONSTOPDCV30 (+), 19 (±)8.0 ~14.5 V
11ABS INONSTOPDCV11 (+), 19 (±)11.5 ~14.5 V
15Ref.ONSTOPDCV15 (+), 19 (±)5 ~9 VConnect ECU
24Ft.(+)ONSTOPDCV24 (+), 19 (±)0.7 ~6 VConnect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
23Rr.(+)ONSTOPDCV23 (+), 19 (±)0.7 ~6 VConnect ECU (off one tooth of speed
sensor ring) and move the vehicle making
sure of voltage change.
18COM(-)ONSTOPDCV18 (+), 19 (±)0VConnect ECU
1VigONSTOPDCV1 (+), 19 (±)8 ~14.5 V
7BRAKEOFFSTOPDCV7 (+), 19 (±)8 ~14.5 VPress brake pedal
21TPSONSTOPDCV21 (+), 19 (±)0.2 ~4.6 VStep on the accelerator pedal and make
sure that voltage changes.
34WD OUTOFFSTOP
3, 197 ~12 k
Disconnect battery GND terminal
5ADC(+)OFFSTOP
5, 1910 ~30
Disconnect battery GND terminal
4SOL(+)OFFSTOP
4, 191.0 ~5.0
Disconnect battery GND terminal
12TOD SWONSTOPDCV12 (+), 19 (±)SW OFF : 0 V
SW ON : 8.0 ~14.5 VSW OFF : Contact point open
SW ON : Contact point close
6LIGHTINGONSTOPDCV6 (+), 19 (±)SW OFF : 8.0 ~14.5
V
SW ON : 0 V
28AUTO INDIONSTOPDCV28 (+), 19 (±)TOD : 0 V
2H & 4L : 8.0 ~14.5
VLighting SW ON : 0V
Lighting SW OFF : 8.0 ~14.5 V
29RR INDIONSTOPDCV29 (+), 19 (±)0 V
17US/JAPOFFSTOP
17 (+), 19 (±)No continuity : OK

5A±5 BRAKE CONTROL SYSTEM
FR
Front Right
GEN
Generator
MV
Millivolts
RL
Rear Left
RR
Rear RightRPS
Revolution per Second
VDC
Volts DC
VA C
Volts AC
W/L
Warning Light
WSS
Wheel Speed Sensor
General Diagnosis
General Information
ABS malfunction can be classified into two types, those
which can be detected by the ABS warning light and those
which can be detected as a vehicle abnormality by the
driver.
In either case, locate the fault in accordance with the
ªBASIC DIAGNOSTIC FLOWCHARTº and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
ABS Service Precautions
Required Tools and Items:

Box Wrench

Brake Fluid

Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
J-39200 High Impedance Multimeter
When circuit measurements are requested, use a circuit
tester with high impedance.
Computer System Service Precautions
The Anti-lock Brake System interfaces directly with the
Electronic Hydraulic Control Unit (EHCU) which is a
control computer that is similar in some regards to the
Powertrain Control Module. These modules are designed
to withstand normal current draws associated with
vehicle operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for opens
or shorts, do not ground or apply voltage to any of the
circuits unless instructed to do so by the appropriate
diagnostic procedure. These circuits should only be
tested with a high impedance multimeter (J-39200) or
special tools as described in this section. Power should
never be removed or applied to any control module with
the ignition in the ªONº position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the ªOFFº
position.
General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure toobserve these precautions may result in Anti-lock Brake
System damage.

If welding work is to be performed on the vehicle using
an electric arc welder, the EHCU and valve block
connectors should be disconnected before the
welding operation begins.

The EHCU and valve block connectors should never
be connected or disconnected with the ignition ªONº .

EHCU of the Anti-lock Brake System are not
separately serviceable and must be replaced as
assemblies. Do not disassemble any component
which is designated as non-serviceable in this
Section.

If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the ªABSº warning light will
illuminate. But actually no trouble exists. After
inspection stop the engine once and re-start it, then
make sure that the ªABSº warning light does not
illuminate.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS to a
non-operative state by removing the fuse for the ABS
(40A). After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning light does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case duplicating
the system malfunction during a test drive or a good
description of vehicle behavior from the customer may be
helpful in locating a ªmost likelyº failed component or
circuit. The symptom diagnosis chart may also be useful
in isolating the failure. Most intermittent problems are
caused by faulty electrical connections or wiring. When
an intermittent failure is encountered, check suspect
circuits for:

Suspected harness damage.

Poor mating of connector halves or terminals not fully
seated in the connector body (backed out).

Improperly formed or damaged terminals.

5C – 10 POWER ASSISTED BRAKE SYSTEM
BLEEDING BRAKE HYDRAULIC SYSTEM
A bleeding operation is necessary to remove air from
the hydraulic brake system whenever air is introduced
into the hydraulic system. It may be necessary to
bleed the hydraulic system at all four brakes if air has
been introduced through a low fluid level or by
disconnecting brake pipes at the master cylinder. If a
brake pipe is disconneted at one wheel, only that
wheel cylinder/caliper needs to be bled. If pipes are
disconnected at any fitting located between master
cylinder and brakes, then the brake system served by
the disconnected pipe must be bled.
1. For 4-wheel Antilock Brake System (ABS)
equipped vehicle, be sure to remove the ABS main
fuse 40A located at the relay and fuse box before
bleeding air. If you attempt to bleed air without
removing the main fuse, air cannot be let out
thoroughly, and this may cause damage to the
hydraulic unit. After bleeding air, be sure to
replace the ABS main fuse back to its original
position.
2. Set the parking brake completely, then start the
engine.
NOTE:
The vacuum booster will be damaged if the bleeding
operation is performed with the engine off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation.
5. Always use new brake fluid for replenishment.
6. In replenishing brake fluid, take care that air
bubbles do not enter the brake fluid.
•When the master cylinder is replaced or
overhauled, first bleed the air from the master
cylinder, then from each wheel cylinder and
caliper following the procedures described
below.
Bleeding the Master Cylinder
7. Disconnect the rear wheel brake pipe 1from the
master cylinder. Check the fluid level and
replenish as necessary. If replenished, leave the
system for at least one minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder where the pipe was disconnected with
your finger, then release the brake pedal slowly.
10. Release your finger from the delivery port when
the brake pedal returns completely.
11. Repeat steps 7 through 9 until the brake fluid
comes out of the delivery port during step 7.
NOTE:
Do not allow the fluid level in the reservoir to go
below the half-way mark.
21

5C – 14 POWER ASSISTED BRAKE SYSTEM
CHECKING BRAKE PEDAL TRAVEL
1. Pedal height (L3) must be measured after starting
the engine and removing it several times to apply
vacuum to the vacuum booster fully.
NOTE:
Pedal height (L3) must be 100 mm (3.9 in)/85 mm (3.5
in) (LHD/RHD) or more when about 50 kg (110.25 lb)
of stepping force is applied.
2. If the measured value is lower than the above
range, air existing in the hydrauic system is
suspected and perform bleeding procedure.
FRONT AND REAR DISC BRAKE PADS
INSPECTION
Check the outer pad by looking at each caliper from
above. Check the thickness on the inner pad by
looking down through the inspection hole in the top of
the caliper. Whenever the pad is worn to about the
thickness of the pad base, the pad should be removed
for further measurements. The pad should be
replaced anytime the pad thickness (t) is worn to
within 1.0 mm (0.039 in) of the pad itself.
The disc pads have a wear indicator that makes a
noise when the pad wears to where replacement is
required.
Minimum Limit mm (in)
1.0 (0.039)
SERVICING THE FRONT BRAKE ROTOR
In the manufacturing of the front brake rotor, all the
tolerances regarding surface finish, parallelism and
lateral runout are held very closely. The maintenance
of these tolerances provide the surface necessary to
assure smooth brake operation.
LATERAL RUNOUT
Lateral runout is the movement of the rotor from side
to side as it rotates on the spindle. This could also be
referred to as “rotor wobble”.
This movement causes the piston to be knocked back
into its bore. This results in additional pedal travel and
a vibration during braking.
t

5C – 42 POWER ASSISTED BRAKE SYSTEM
REMOVAL
•Before removing the vacuum booster assembly,
disconnect and remove brake pipes.
1. Master Cylinder
•Refer to Master Cylinder Assembly in this Section.
CAUTION:
When removing master cylinder from vacuum booster,
be sure to get rid of the internal negative pressure of
the vacuum booster (by, for instance, disconnecting
vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing master cylinder, further, do not hold
the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
2. Vacuum Hose
3. Yoke Clevis
•Disconnect the yoke clevis from the brake pedal.
4. Vacuum Booster Fixing Nut
5. Vacuum Booster
INSPECTION AND REPAIR
Vacuum Hose
Inspect the check valve (1), which is installed inside
the vacuum hose.
1) Air should pass freely from the vacuum booster
side (3) to the engine side (2).
2) Air should not pass from the engine side (2) to the
vacuum booster side (3). If it does, the check valve
is inoperative and vacuum hose must be replaced.
INSTALLATION
5. Vacuum Booster
Vacuum booster push rod adjustment.
NOTE:
When replacing either master cylinder or vacuum
booster, be sure to measure push rod, and adjust
required.
Push rod gauge: 5-8840-2300-0 (J-39216)
Vacuum pump: 5-8840-0279-0 (J-23738-A)
Push rod support: 5-8840-2305-0 (J-39241)
1) Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate
and seal assembly out of the shell inside.
ENG
1
2 3
360RX001

6A±41
ENGINE MECHANICAL
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
4. Remove three fixing bolts, oil pipe with O-ring.
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly, before
removing the bearing cap, remove carbon on the top
of cylinder bore and push piston with connecting rod
out from the top of cylinder bore.
Installation
1. Install piston with connecting rod assembly.

Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.

The bearing cap number must be the same as
connecting rod number.

Apply engine oil to the thread and seating surface of
each nut.

Tighten nuts to the specified torque.
Torque : 54 N´m (5.5 Kg´m/40 lb ft)

After tightening the nuts, make sure that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces
and connecting rod bearing fitting surfaces.
015RW003
Legend
(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark
2. Install oil gallery and tighten the bolts in two steps, in
the order shown in illustration.
Torque :
1st step : 29 N´m (3.0 Kg´m/21 lb ft)
2nd step : 55
±65

051RS009
3. Install oil pipe with O-ring.
Torque : 10 N´m (1.0 Kg´m/89 lb in)
4. Install oil strainer assembly with O-ring.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
5. Install crankcase with Oil Pan.

Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.

Refer to installation procedure for Cylinder Head in
this manual.

6A±47
ENGINE MECHANICAL
Rear Oil Seal
Removal
1. Remove transmission assembly.

Refer to removal procedure for Transmission
section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
5±8840±2286±0.
015RS017
2. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on the crankshaft and flywheel
mounting surface.

Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
Torque : 54 N´m (5.5 Kg´m/40 lb ft)
015RS018
3. Install transmission.

See Transmission section in this manual.
CAUTION: W h e n assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
012RS009