Isuzu Rodeo (4wd) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993) ) PDF

Factory Workshop Manual
Make
Isuzu
Model
Rodeo (4wd)
Engine and year
V6-3165cc 3.2L SOHC (6VD1) (1993)
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Date
1st January 2018
Isuzu Rodeo (4wd) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993))
Isuzu Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > System Information > System
Diagnosis
Codes by System: Testing and Inspection
For diagnosis of all P codes

Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Electronic Brake Control Module: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
Circuit schematics break the entire electrical system into individual circuits. Electrical components
that work together are shown together.
CURRENT FLOW
Each drawing is arranged so current flows from positive, at top of page to ground, at bottom. The
"hot" labels at the top of a fuse indicate when the ignition switch supplies power to that fuse.
CIRCUIT NETWORKING
Wires that connect to another circuit are shown with an arrowhead pointing in the direction of
current flow. The name of the circuit that shares the wiring is shown for reference.
POWER AND GROUND SUPPLY
"See Fuse Box Details" indicates there are connections to other circuits that are not shown. All
shared circuits are shown on the Fuse Box Details schematic. "See Ground Distribution" indicates
there are shared ground circuits which are shown on the ground distribution schematic.
CIRCUIT/COMPONENT LOCATION
No attempt is made to represent the location or proximity of components. If a wire is actually 4 foot
or 4 inches, it will be represented without regard in the schematic.
Component/Connector Location and I.D.
COMPONENT AND CONNECTOR LOCATION
Supplied with the wiring schematic is a component location index. The index lists the correct
photograph for the components and connectors listed. The photographs are illustrated in
COMPONENT/CONNECTOR I.D. AND LOCATION.
HARNESS ROUTING
Harness routing and selected connectors related to the system are illustrated in this section. The
connectors are illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION.
CONNECTOR I.D.
All connectors with more than 2 terminals are illustrated in this section. The connectors are
illustrated in COMPONENT/CONNECTOR I.D. AND LOCATION.
Fuse Box Details
The fuse box details schematic shows all the wiring between a fuse and the components
connected to the output side of the fuse. It shows what supplies power to the fuse and when it is
energized.
Ground Distribution
The ground distribution schematics show which components share a common ground point. This
information can be very helpful in diagnosing inoperative circuits. If more than one components are
not working and they share a common ground, it is likely the ground circuit is faulty. However, if
one of the circuits is operative and the other is not, you know the ground and the wire are good up
to a splice.
Light Switch Details
The light switch details schematic shows all the wiring between the light switch/relays and the
components connected to the output side of the light switch/relays.
Power Distribution
The Power distribution schematic shows the wiring from the battery and alternator to the:
- Starter solenoid - Fuse box - Light switch - Ignition switch - Fuse link
The first component after a fuse link is shown. In certain instances, the first component after a fuse
box, fuse and light switch is shown.
All fuses in the schematic are "Hot At All Times", since battery voltage is the direct source.
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12
Symbol Identification
Wire Color Code Identification

Black: BLK Blue: BLU Brown: BRN Clear: CLR Gray: GRY Green: GRN Light Blue: LT BLU Light
Green: LT GRN Orange: ORN Pink: PNK Red: RED
White: WHT Yellow: YEL
Electronic Brake Control Module: Diagnostic Aids
Continuity and Resistance Check
Meter Types
1. Use a digital or analog multimeter with a minimum 10k ohm resistance.
2. Disconnect the battery or connector so there is no power between the check points.
3. Set the ohmmeter to the appropriate range.
Continuity And Resistance Check
4. Connect the two leads of the meter to each of the check points.
Diode Check
5. If the circuit or component has diodes, reverse the leads and check again. a. When contacting
the negative lead to the diode's positive side and the positive lead to the negative side, there
should be continuity. b. When connecting the two leads in reverse, there should not be continuity.
Electronic Component Handling
STATIC DISCHARGE
^ Discharge any static electrical charges before handling electronic parts by touching ground or
maintaining a ground connection to a bare skin area like the wrist.
^ Never touch the ECU connector pins, integrated circuit connector pins, or soldered components
on the ECU circuit board.
TESTING
^ When measuring voltage at the control unit harness connector, disconnect harness connector
with the ignition OFF, then turn ignition "ON" as necessary.
^ To prevent deforming control unit harness connectors, do not probe terminals directly. Instead,
insert a pin from the harness side and perform measurements through pin.
CONTROL UNIT DAMAGE
^ Do not try to disassemble the control unit.
^ Before performing electrical welding (for instance, spot welding), disconnect the battery, climate
control, injection, cruise control, ECU and radio.
^ If temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all ECU's.
^ Avoid getting water on any of the Fuel and Engine Control System Components.
^ Never apply battery power to a component unless directed to do so in a test procedure.
Electronic Component Replacement
1. Before servicing electronic components, disconnect the battery ground.
NOTE: Before removing battery ground, access trouble codes. ECU memory will be erased if
ground cable is removed.
2. Fuel and Engine Control System wiring should be at least 4 inches away from ignition wires.
Battery Precautions
CAUTION: -
Never use a booster/starter which has a voltage rating above 12 volts to start engine.
- Always ensure the battery is properly connected to the vehicle prior to attempting to start engine.
- Don't disconnect the battery when the engine is running.
- When charging a battery, be sure battery cables are disconnected.
- The battery contains acid and produces explosive gas (hydrogen). Avoid creating sparks near
battery.
Electrical Connections and Circuits
1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all
insulators and shields are in place when reinstalling.
2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position
unless specifically directed to do so in a test procedure.
3. Do not use a self powered test lamp to check continuity.
4. Do not create any arcing to check the continuity of a circuit.
Electrostatic Discharge
ELECTROSTATIC DISCHARGE
Electronic components used in automotive computers are designed to operate at very low voltages
(3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as
low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of
static discharge for a person to even feel the "ZAP", and there is no way of knowing whether the
charge is positive or negative in nature.
There are several ways in which a person can become statically charged. The most common
methods of charging are by friction and induction.
CHARGING BY FRICTION
Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl,
or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding
across a car seat or by wearing a cotton shirt under a coat made of synthetic materials.
CHARGING BY INDUCTION
Charging by induction occurs when a person standing near a highly charged object (strong
magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to
ground, leaving the person highly charged with opposite polarity.
PRECAUTIONS
Static charges are gradually equalized by moisture in the air, but are retained much longer when
humidity is low. Use care when handling and
testing electronic components.
Proper Tools and Testing Procedures
DIGITAL VOLT/OHM METER
Use a digital volt/ohm meter (DVOM) with a minimum 10 mega-ohms internal impedance when
testing an ECU or related components, unless use of an analog meter is specified by a testing
procedure. Analog meters have low internal impedance and cause circuit "loading" in low voltage
circuits, resulting in inaccurate measurements and possible damage to components. Use of a
DVOM is necessary to obtain accurate measurements and avoid damaging low voltage ECU
circuits and components.
TESTING PROCEDURES
Always follow recommended testing procedures. Never ground or apply voltage to a circuit unless
specified by a testing procedure. ECU's provide a regulated constant low voltage source to some
circuits, which may require a minimum resistance (impedance) to operate. Directly grounding or
applying battery power to these circuits could damage the ECU and cause a system failure.
Finding Short Circuits
Meter Types
2. Remove the blown fuse and disconnect all loads for that circuit.
Finding A Short Circuit
3. Connect a test lamp in place of the fuse.
4. Establish conditions that turn the test lamp on.
EXAMPLE
a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect

the relay)
5. Connect and disconnect the components or connectors in the circuit while watching the test light.
a) The test light will come on when the shorted circuit or component is connected. b) The test light
will go off when the circuit or component is disconnected
Voltage Check
Meter Types
Voltage Check
2. Establish conditions in which voltage should be present at the check point.
EXAMPLE:
a) Ignition SW ON b) Ignition SW and SW 1 ON c) Ignition SW, SW1 and Relay ON (SW 2 OFF)
3. Set the volt meter to the appropriate range for the circuit being tested.
4. Connect the negative lead to a good ground point or the negative battery terminal, and connect
the positive lead to the connector or component terminal. NOTE: This test can be done with a test
light if the circuit does not include sensitive electrical components, i.e. electrical control units.
Circuit Protection Devices
PURPOSE
The purpose of circuit protection is to protect the wiring assembly during normal and overload
conditions. An overload is defined as a current requirement that is higher than normal. This
overload could be caused by a short circuit or system malfunction. The short circuit could be the
result of a pinched or cut wire or an internal device short circuit, such as an electronic module
failure. The circuit protection device is only applied to protect the wiring assembly, and not the
electrical load at the end of the assembly. For example, if an electronic component short circuits,
the circuit protection device will assure a minimal amount of damage to the wiring assembly.
However, it will not necessarily prevent damage to the component.
CIRCUIT PROTECTION DEVICES
There are three basic types of circuit protection devices: Circuit Breaker, Fuse and Fusible Link.
CIRCUIT BREAKERS
A circuit breaker is a protective device designed to open the circuit when a current load is in excess
of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the
excessive current will open the circuit between the circuit breaker terminals. There are two basic
types of circuit breakers used in this vehicle: cycling and non-cycling.
Cycling Circuit Breaker

The cycling breaker will open due to heat generated when excessive current passes through it for a
period of time. Once the circuit breaker cools, it will close again after a few seconds. If the cause of
the high current is still present it will open again. It will continue to cycle open and closed until the
condition causing the high current is removed.
Non-Cycling Circuit Breaker
There are two types of non-cycling circuit breakers. One type is mechanical and is nearly the same
as a cycling breaker. The difference is a small heater wire within the non-cycling circuit breaker.
This wire provides enough heat to keep the bimetallic element open until the current source is
removed. The other type is solid state, known as an Electronic Circuit Breaker (ECB). This device
has a Positive Temperature Coefficient. It increases its resistance greatly when excessive current
passes through it. The excessive current heats the ECB. As it heats, its resistance increases,
therefore having a Positive Temperature Coefficient. Eventually the resistance gets so high that the
circuit is effectively open. The EC13 will not reset until the circuit is opened, removing voltage from
its terminals. Once voltage is removed, the circuit breaker will re-close within a second or two.
Fig. 1 Fuse Devices

Fig. 2 Fuse Rating and Color
FUSES
The most common method of automotive wiring circuit protection is the fuse, Fig. 1. A fuse is a
device that, by the melting of its element, opens an electrical circuit when the current exceeds a
given level for a sufficient time. The action is non-reversible and the fuse must be replaced each
time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The
standardized color identification and ratings are shown in Fig. 2. For service replacement,
non-color coded fuses of the same respective current rating can be used. Examine a suspect fuse
for a break in the element. If the element is broken or melted, replace the fuse with one of equal
current rating. There are additional specific circuits with in-line fuses. These fuses are located
within the individual wiring harness and will appear to be an open circuit if blown.
Autofuse
The Autofuse, normally referred to simply as "Fuse," is the most common circuit protection device
in today's vehicle. The Autofuse is most often used to protect the wiring assembly between the
Fuse Block and the system components.
Maxifuse
The Maxifuse was designed to replace the fusible link and Pacific Fuse Elements. The Maxifuse is
designed to protect cables, normally between the Battery and Fuse Block, from both direct short
circuits and resistive short circuits. Compared to a fusible link or a Pacific Fuse Element, the
Maxifuse performs much more like an Autofuse, although the average opening time is slightly
longer. This is because the Maxifuse was designed to be a slower blowing fuse, with less chance
of nuisance blows.
Minifuse
The Minifuse is a smaller version of the Autofuse and has a similar performance. As with the
Autofuse, the Minifuse is usually used to protect the wiring assembly between a Fuse Block and
system components. Since the Minifuse is a smaller device, it allows for more system specific
fusing to be accomplished within the same amount of space as Autofuses.
Pacific Fuse Element
The Pacific Fuse Element was developed to be a replacement for the fusible link. Like a fusible
link, the fuse element is designed to protect
wiring from a direct short to ground. Though the element is easier to service and inspect than a
fusible link, it has limited use and will be replaced by Maxifuses in future vehicles.
Fig. 3 Good and Damaged Fusible Links

Fig. 6 Wire Size Conversion Table
FUSIBLE LINKS
In addition to circuit breakers and fuses, some circuits use fusible links to protect the wiring. Like
fuses, fusible links are "one-time" protection devices that will melt and create an open circuit, Fig.
3. Not all fusible link open circuits can be detected by observation. Always inspect that there is
battery voltage past the fusible link to verify continuity. Fusible links are used instead of a fuse in
wiring circuits that are not normally fused, such as the ignition circuit. For AWG sizes, each fusible
link is four wire gage sizes smaller than the wire it is designed to protect. For example: to protect a
10 gage wire use a 14 gage link or for metric, to protect a 5 sq mm wire use a 2 sq mm link, Fig. 6.
Links are marked on the insulation with wire gage size because the heavy insulation makes the link
appear to be a heavier gage than it actually is. The same wire size fusible link must be used when
replacing a blown fusible link. Fusible links are available with three types of insulation: Hypalon(R),
Silicone/GXL (SIL/GXL) and Expanded Duty. All future vehicles that use fusible links will utilize the
Expanded Duty type of fusible link. When servicing fusible links, all fusible links can be replaced
with the Expanded Duty type. SIL/GXI fusible links can be used to replace either SIL/GXI or
Hypalon(R) fusible links. Hypalon(R) fusible links can only be used to replace Hypalon(R) fusible
links.
Determining characteristics of the types of fusible links:
^ Hypalon(R) (limited use): only available in .35 sq mm or smaller and its insulation is one color all
the way through.
^ SIL/GXL (widely used): available in all sizes and has a white inner core under the outer color of
insulation.
^ Expanded Duty: available in all sizes, has an insulation that is one color all the way through and
has three dots following the writing on the insulation.
Service fusible links are available in many lengths. Choose the shortest length that is suitable. If
the fusible link is to be cut from a spool, it should be cut 150-225 mm (approx 6-9 in.) long. NEVER
make a fusible link longer than 225 mm (approx 9 in.).
CAUTION: Fusible links cut longer than 225 mm (approx 9 in.) will not provide sufficient overload
protection.
Fig. 4 Single Wire Feed Fusible Link
Fig. 5 Double Wire Feed Fusible Link
SERVICE PROCEDURE
- To replace a damaged fusible link, Fig. 4, cut it off beyond the splice. Replace with a repair link.
When connecting the repair link, strip wire and use staking-type pliers to crimp the splice securely
in two places. For more details on splicing procedures, see SPLICING COPPER WIRE. Use Crimp
and Seal splices whenever possible.
- To replace a damaged fusible link which feeds two harness wires, cut them both off beyond the
splice. Use two repair links, one spliced to each harness wire, Fig. 5.
Typical Electrical Repair
An open circuit is an incomplete circuit. Power cannot reach the load or reach ground. If a circuit is
open, active components do not energize. A short circuit is an unwanted connection between one
part of the circuit and either ground or another part of the circuit. A short circuit causes a fuse to
blow or a circuit breaker to open.
SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION
- Locate the damaged wire.
- Find and correct the cause of the wire insulation damage.
- For minor damage, tape over the wire. If damage is more extensive, replace the faulty segment of
the wire (Refer to the splicing instructions for copper or shielded cable for the correct splicing
procedure).
Splicing Copper Wire Using Splice Clips
The Splice Clip is a general purpose wire repair device. It may not be acceptable for applications
having special requirements such as moisture sealing.
Step 1: Open the Harness
If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing "seam
ripper" to cut open the harness (available from sewing supply stores). If the harness has a black
plastic conduit, simply pull out the desired wire.
Step 2: Cut the Wire
Begin by cutting as little wire off the harness as possible. You may need the extra length of the wire
later if you decide to cut more wire off to change the location of a splice. You may have to adjust
splice locations to make certain that each splice is at least 40 mm (1-1/2") away from other splices,
harness branches or connectors.
Step 3: Strip the Insulation
When replacing a wire, use a wire of the same size as the original wire or larger. The schematics
list wire size in metric units. See table, Fig. 6, for the commercial (AWG) wire sizes that can be
used to replace each metric wire size. Each AWG size is either equal to or larger than the
equivalent metric size. To find the correct wire size either find the wire on the schematic and
convert the metric size to the AWG size, or use an AWG wire gage. If you aren't sure of the wire
size, start with the largest opening in the wire stripper and work down until a clean strip of the
insulation is removed. Be careful to avoid nicking or cutting any of the wires.
Fig. 8 Crimping the Splice Clip

Fig. 9 Completing the Crimp
Step 4: Crimp the Wires
Select the proper clip to secure the splice. To determine the proper clip size for the wire being
spliced, follow the directions included in the J 38125-A Terminal Repair Kit. Select the correct anvil
on the crimper. On most crimpers your choice is limited to either a small or large anvil. Overlap the
stripped wire ends and hold them between your thumb and forefinger as shown in Fig. 7. Then,
center the splice clip under the stripped wires and hold it in place. ^
Open the crimping tool to its full width and rest one handle on a firm flat surface.
^ Center the back of the splice clip on the proper anvil and close the crimping tool to the point
where the former touches the wings of the clip.
^ Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until
the crimping tool closes, Fig. 8.
^ Before crimping the ends of the clip, be sure that: -
The wires extend beyond the clip in each direction.
- No strands of wire are cut loose, and
- No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the
crimping tool extend beyond the edge of the clip or you may damage or nick the wires, Fig. 9.
Step 5: Solder
Apply 60/40 rosin core solder to the opening in the back of the clip, Fig. 10. Follow the
manufacturer's instruction for the solder equipment you are using.
Fig. 11 Proper First Taping
Fig. 12 Proper Second Taping
Step 6: Tape the Splice
Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to
duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape
may not provide enough insulation, and the nagged ends will tangle with the other wires in the
harness, Fig. 11. If the wire does not belong in a conduit or other harness covering, tape the wire
again. Use a winding motion to cover the first piece of tape, Fig. 12.
Splicing Copper Wire Using Crimp and Seal Splice Sleeves
Crimp and Seal splice sleeves may be used on all types of insulation except tefzel and coaxial to
form a one to one splice. They are to be used where there are special requirements such as
moisture scaling.
ripper" to cut open the harness (available from sewing supply stores). The Crimp and Seal splice
sleeves may be used on all types of insulation except tefzel and coaxial and may only be used to
form a one to one splice.
Begin by cutting as little wire off the harness as possible. You may need the extra length of wire
later if you decide to cut more wire to change the location of a splice. You may have to adjust splice
locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices,
harness branches or connectors. This will help prevent moisture from bridging adjacent splices and
causing damage.

If it is necessary to add a length of wire to the existing harness, be certain to use the same size as
the original wire, see Fig. 6. To find the correct wire size either find the wire on the schematic and
convert the metric size to the equivalent AWG size or use an AWG wire gage. If unsure about the
wire size, begin with the largest opening in the wire stripper and work down until a clean strip of the
insulation is removed. Strip approximately 7.5 mm (5/16 in.) of insulation from each wire to be
spliced. Be careful to avoid nicking or cutting any of the wires. Check the stripped wire for nicks or
cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.
Fig. 13 Hand Crimp Tool
Fig. 14 Seal Splice Sequence
Step 4: Select and Position the Splice Sleeve

Select the proper splice sleeve according to wire size. The splice sleeves and tool nests are color
coded. Using a crimp tool, Fig. 13, position the splice sleeve in the proper color nest of the hand
crimp tool. Place the splice sleeve in the nest so that the crimp falls midway between the end of the
barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going
further, Fig. 14. Close the hand crimper handles slightly to hold the splice sleeve firmly in the
proper nest.
Step 5: Insert Wires into Splice Sleeve and Crimp
Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the crimper
tightly until the crimper handles open when released. The crimper handles will not open until the
proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of
the splice.
Step 6: Shrink the Insulation around the Splice
Using a suitable heat gun, apply heat where the barrel is crimped. Gradually move the heat barrel
to the open end of the tubing, shrinking the tubing completely as the heat is moved along the
insulation. A small amount of sealant will come out of the end of the tubing when sufficient
shrinking is achieved, Fig. 14.
Splicing Twisted/Shielded Cable

Fig. 15 Twisted/Shielded Cable
Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For
example, two-conductor cable of this construction is used between the ECM and the distributor.
See Fig. 15 for a breakdown of twisted/shielded cable construction.
Step 1: Remove Outer Jacket
Remove the outer jacket and discard it. Be careful to avoid cutting into the drain wire or the mylar
tape.
Step 2: Unwrap the Tape
Unwrap the aluminum/mylar tape, but do not remove it. The tape will be used to rewrap the twisted
conductors after the splices have been made.
Fig. 16 The Untwisted Conductors
Step 3: Prepare the Splice
Untwist the conductors. Then, prepare the splice by following the splicing instructions for copper
wire presented earlier. Remember to stagger splices to avoid shorts, Fig. 16.
Fig. 17 The Re-assembled Cable
Step 4: Re-assemble the Cable
After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful
to avoid wrapping the drain wire in the tape. Next, splice the drain wire following the splicing
instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape, Fig.
17.
Fig. 18 Proper Taping
Step 5: Tape the Cable
Tape over the entire cable using a winding motion, Fig. 18. This tape will replace the section of the
jacket you removed to make the repair.
Repairing Connectors
The following general repair procedures can be used to repair most types of connectors. The repair
procedures are divided into three general groups: Push-to-Seat and Pull-to-Seat and Weather
Pack.
^ See CONNECTOR TERMINAL I.D. to determine which type of connector is to be serviced.
^ Use the proper Pick(s) or Tool(s) that apply to the terminal.

Figure 1 - Typical Push-To-Seat Connector
Fig. 20 Typical Pull-to-Seat Connector and Terminal
PUSH-TO-SEAT AND PULL-TO-SEAT
Follow the steps below to repair Push-to-Seat or Pull-to-Seat connectors, Figs. 19 and 20. The
steps are illustrated with typical connectors. Your connector may differ, but the repair steps are
similar. Some connectors do not require all the steps shown. Skip those that don't apply.
1. Remove any CPA (Connector Position Assurance) Locks. CPAs are designed to retain
connectors when mated.
2. Remove any TPA (Terminal Position Assurance) Locks. TPAs are designed to keep the terminal
from backing out of the connector.
NOTE: The TPA must be removed prior to terminal removal and must be replaced when the
terminal is repaired and reseated.
3. Open any secondary locks. A secondary lock aids in terminal retention and is usually molded to
the connector.
4. Separate the connector halves and back out seals.
5. Grasp the lead and push the terminal to the forward most position. Hold the lead at this position.
6. Locate the terminal lock tang in the connector canal.
7. Insert the proper size pick straight into the connector canal at the mating end of the connector.
8. Depress the locking tang to unseat the terminal. Push-to-Seat - Gently pull on the lead to
remove the terminal through the back of the connector. Pull-to-Seat - Gently push on the lead to
remove the terminal through the front of the connector.
NOTE: Never use force to remove a terminal from a connector.
9. Inspect terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR.
10. Reform lock tang and reseat terminal in connector body. Apply grease if connector was
originally equipped with grease.
11. Install any CPAs or TPAs, close any secondary locks and join connector halves.
Fig. 21 Typical Weather Pack Connector and Terminal

WEATHER PACK
Follow the steps below to repair Weather Pack(R) connectors, Fig. 21.
1. Separate the connector halves.
2. Open secondary lock. A secondary lock aids in terminal retention and is usually molded to the
connector.
4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector
cavity until it rests on the cavity shoulder.
5. Gently pull on the lead to remove the terminal through the back of the connector.
6. Inspect the terminal and connector for damage. Repair as necessary, see TERMINAL REPAIR.
7. Reform the lock tang and reseat terminal in connector body.
8. Close secondary locks and join connector halves.
Terminal Repair
Fig. 22 Terminal Repair

The following repair procedures can be used to repair Push-to-Seat, Pull-to-Seat or Weather
Pack(R) terminals, Fig. 22. Some terminals do not require all steps shown. Skip those that don't
apply. (Refer to Kent-Moore Terminal Repair Kit J 38125-A for further information.)
1. Cut off terminal between core and insulation crimp (minimize wire loss) and remove seal for
Weather Pack(R) terminals.
2. Apply correct seal per gauge size of wire and slide back along wire to enable insulation removal
(Weather Pack(R) terminals only).
3. Remove insulation.
4. Align seal with end of cable insulation (Weather Pack(R) terminals only).
5. Position strip (and seal for Weather Pack(R)) in terminal.
6. Hand crimp core wings.
7. Hand crimp insulation wings (non-Weather Pack(R)). Hand crimp insulation wings around seal
and cable (Weather Pack(R)).
8. Solder all hand crimped terminals.

Electronic Brake Control Module: Electrical Diagrams
Fig. 29 RWAL system wiring diagram.

Fig. 47 RWAL wiring diagram. W/RWAL
Control Module > Component Information > Diagrams > Page 34
Electronic Brake Control Module: Service and Repair
1. Remove passenger seat assembly. 2. Disconnect ECM harness connector. 3. Remove ECM
bracket retaining bolts, then ECM. 4. Reverse procedure to install, torque passenger seat retaining
bolts to 29 ft. lbs.
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Compressor Clutch Relay: Locations
Picture 19
Fuse Panel
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC >
Component Information > Locations
Condenser Fan Motor Relay: Locations
Picture 15
Fuse Panel
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component
System Relay: Locations
Picture 15
Fuse Panel
Information > Testing and Inspection > Heater Relay
System Relay: Testing and Inspection Heater Relay
HEATER RELAY
1. Disconnect the heater relay (X-2). 2. Check for continuity between the terminals of heater relay.
Check for continuity between the terminals of heater relay.

Information > Testing and Inspection > Heater Relay > Page 47
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules -
Computers and Control Systems > Engine Control Module > Component Information > Specifications
Engine Control Module: Specifications

ECM Connector Identification
Check voltage at the connector terminals as listed, under the stated conditions with the Engine
Control Module (ECM) connected. Measure voltage with a Digital Volt Ohm Meter (DVOM) through
a "break-out box" or use a straight pin inserted from the back of the connector into the appropriate
terminal.
CAUTION: Do not short between terminals! Damage to the ECM may result.
Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page 53
Engine Control Module: Locations
ECM
In the L.H. kick panel.

Engine Control Module: Description and Operation
Inputs And Outputs
PURPOSE
Control unit of fuel injection system.
OPERATION
It constantly looks at information from various sensors, and controls systems that affect vehicle
performance. The Engine Control Module (ECM) also performs diagnostic function of system. It
can recognize operational problems, alert driver through "Check Engine" light, and store a code or
codes which identify problem areas to aid technician in making repairs.
ECM supplies either 5 or 12 volts to power various sensors or switches and controls output circuits
such as fuel injectors, Idle Air Control (IAC) valve, A/C clutch relay, etc. by controlling ground circuit
through transistors or a "quad-driver".
Engine Control Module: Testing and Inspection
IMPORTANT NOTE!
The Engine Control Module (ECM) is a highly efficient component and replacement is rarely
needed. ECM failure is usually caused by another component. If an ECM is found to be faulty, be
sure to inspect all input and output circuits prior to installation of the the new ECM. Installing a new
ECM without correcting another possible problem will cause repeated ECM failure.
ECM TESTING
The ECM is a transistorized computer component. There are no specific testing procedures.
Diagnostic codes 51 indicate a faulty ECM or EEPROM. If this code is present, check that all ECM
connections are good, clear memory and recheck. If code 51 reappears, replace the ECM.
Always think of the ECM as the last possible source of a problem. Rarely do they fail.
Engine Control Module: Service and Repair
ECM
This component is non-serviceable and must be replaced as a unit, do not try to disassemble
components.
REMOVAL
1. Negative battery cable
2. Lower left trim panel
3. Disconnect ECM harness connector.
4. Remove ECM bracket retaining bolts, then ECM.
NOTE: To prevent possible Electronic Discharge damage to the ECM, Do not touch the connector
pins or soldered components on the circuit board.
INSTALLATION
1. ECM
2. ECM electrical connectors (2)

Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Fuse Panel
In fuse/relay center in engine compartment.

Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 60
Main Relay (Computer/Fuel System): Description and Operation
PURPOSE
Provides power to the Engine Control Module (ECM) and other components.
OPERATION
When the key is turned ON, the relay coil inside the relay energizes. This closes the contacts in the
relay and supplies power to the ECM, Fuel Injectors, and Oxygen Sensor heater.
Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Fuse Panel

Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 65
Fuel Pump Relay: Description and Operation
Fuel Pump Circuit
PURPOSE
Allows the ECM control over fuel pump operation.
Fuel Pump Relay Connector
LOCATION
In the fuse/relay center, in the engine compartment.

OPERATION
When ignition is switched "RUN" position (engine not running), ECM energizes fuel pump relay for
two seconds, causing fuel pump to pressurize fuel system. If ECM does not receive ignition
reference pulses (engine cranking or running) within two seconds, it will de-energize relay, stopping
fuel pump.
After the engine starts, the ECM uses the signal from the electronic ignition module to determine if
the engine is running. If the signal is interrupted, the ECM will not energize the fuel pump. This
prevents the fuel from operating when the engine is not running.
Fuel Pump Relay: Testing and Inspection
Fuel Pump Circuit

Chart A-5 Fuel Pump Relay Circuit
Circuit Description
When the ignition switch is turned "ON", the Engine Control Module (ECM) will activate the fuel
pump relay and operate the in tank fuel pump. The fuel pump will operate as long as the engine is
cranking or running and the ECM is receiving ignition reference pulses. If there are no reference
pulses, the ECM will shut "OFF" the fuel pump within 2 seconds after key "ON".
Test Description
Numbers below refer to circled numbers on the diagnostic chart.
1. Checks for the presence Battery Position Voltage at switching portion of fuel pump relay.
2. Checks circuit between fuel pump relay and ground (including the fuel pump).
3. This test will confirm if voltage is available to the relay coil.
Diagnostic Aids
A visual inspection of wiring and connectors should be made if an intermittent problem exists. For
more information refer to Computers and Control Systems.
Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Fuse Panel

Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 71
PURPOSE
OPERATION
Ignition System > Ignition Control Module > Component Information > Locations
Ignition Control Module: Locations
Coil Pack
Under ignition coil pack, at front of engine.

Ignition System > Ignition Control Module > Component Information > Locations > Page 76
Ignition Control Module: Description and Operation
PURPOSE AND OPERATION
Electronic Ignition Control Module (ICM) turns ON / OFF primary circuit of ignition coils, and also
controls ignition timing at engine speed below 538 rpm.
Ignition System > Ignition Control Module > Component Information > Locations > Page 77
Ignition Control Module: Service and Repair
REMOVE OR DISCONNECT
1. Negative Battery Cable. 2. Electronic Ignition Assembly from intake plenum. 3. Coils from
assembly. 4. Module from assembly plate.
REFIT
1. Reverse procedure.
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Electrical Test Equipment
Air Bag Control Module: Service Precautions Electrical Test Equipment
When using electrical test equipment, insert the probe of the tester into the wire side of the
connector. Do not insert the probe of the tester into the terminal side of the connector, and do not
tamper with the connector. Inserting the probe into the terminal side of the connector, and
tampering the connector could cause malfunction of the SRS system or an error in inspection.
Use a probe with the correct tip. Do not insert the probe forcibly.
Use specified service connectors in troubleshooting. Using tools which are not specified standard
design could cause an error in inspection due to poor metal-to-metal contact.
Component Information > Service Precautions > Electrical Test Equipment > Page 83
Air Bag Control Module: Service Precautions Wiring
Never attempt to modify, splice or repair SRS wiring.
NOTE: SRS wiring can be identified by special yellow outer protective covering.
Be sure to install the harness wires so that they are not pinched or interfering with other parts.
Make sure all SRS ground locations are clean and grounds are securely fastened for optimum
metal-to-metal contact. Poor grounding can cause intermittent problems that are difficult to
diagnose.
Component Information > Service Precautions > Page 84
Air Bag Control Module: Description and Operation
Deployment Loop and Sensing and Diagnostic Module
The deployment loop and Sensing and Diagnostic Module (SDM) are the two main portions of the
Supplemental Restraint System (SRS). The deployment loop portion supplies current through the
SRS modules, which are used to deploy the air bags in the event of a front end collision of
sufficient force up to 30 ° off vehicle centerline.
Fig. 2 Deployment Loop Diagram
The deployment loop consists of the arming sensor, SRS coil, inflator modules and discriminating
sensors, Fig. 2. The arming sensor switches power to the inflator modules on the deployment loop
high side.
Either of the discriminating sensors may provide ground to the inflator modules on the deployment
loop low side. The modules will only be supplied sufficient current to deploy when the arming
sensor and at least one of the two discriminating sensors closes simultaneously for three
milliseconds or more.
The Sensing and Diagnostic Module (SDM) contains a 24 Volt Loop Reserve (24 VLR) and a
sensing device to convert vehicle velocity changes to electrical signals. These are processed by
the SDM and compared to a value stored in memory. If the generated signal exceeds the stored
value, the SDM
sends current flow to the air bags and deploys them.
Air Bag Control Module: Testing and Inspection
To ensure proper system operation on any vehicle involved in a collision, all system components
should be inspected for dents, cracks, exposure to excessive heat and other damage even if
deployment did not take place. The steering column, knee pad and instrument panel reinforcement
plate should be inspected for damage. All air bag system wiring should be checked for chaffing and
interference with other vehicle components. Do not attempt to repair forward discriminating sensor,
passenger compartment discriminating sensor, arming sensor, DERM, coil assembly, SIR module
or mounting brackets. If found to be damaged, replace with a new unit. To ensure proper operation
of the SIR system, the vehicle structure must be returned to its original configuration. When
repairing vehicle, the SIR system should be disarmed as outlined under Technician Safety
Information. Also, when performing service procedure, do not expose components or wiring to heat
guns, welding or spray guns.
Air Bag Control Module: Service and Repair
1. Disarm SRS as outlined under Technician Safety Information. 2. Remove Powertrain Control
Module (PCM) cover cap and cover, then disconnect harness connectors. 3. Remove PCM unit
with three bolts. 4. Disconnect sensor connector, remove three bolts, then remove sensor from
vehicle. 5. Reverse procedure to install. Tighten attaching screws to specifications. 6. Arm SRS as
outlined under Technician Safety Information.
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control
Module Identification
Control Module: Technical Service Bulletins A/T - (4L30E) Control Module Identification
BULLETIN NUMBER SB96-05-L001
ISSUE DATE JANUARY 1996
GROUP TRANSMISSION
4L30-E AUTOMATIC TRANSMISSION/TRANSMISSION CONTROL MODULE IDENTIFICATION

CHART
AFFECTED VEHICLES
1990-91 Trooper II (KT), 1992-95 Trooper (UX), 1991-95.5 Rodeo (UC) models equipped with
4L30-E automatic transmission.
SERVICE INFORMATION
When replacing 4L30-E automatic transmissions or transmission control modules (TCMs), it is

important to order the appropriate replacement parts. Failure to pair the proper TCM or
transmission with its proper counterpart can result in poor transmission performance.
Module Identification > Page 94
This Service Bulletin provides important identification data to ensure that a proper pairing of
transmission and TCM is always made. Figures 1 through 3 show the typical location of the
identification plate on both the transmission and TCM. Figure 1 shows the typical location on
transmissions and TCMs manufactured by Bosch for 1990-93 MY vehicles. Figures 2 and 3 show
the typical location on transmissions and TCMs manufactured by Delco Electronics for 1994 and
1995-95.5 MY vehicles respectively.
The chart provides an extensive listing of 4L30-E automatic transmissions and their TCM
counterparts. When ordering a replacement part, use the chart as shown:
^ Select the appropriate vehicle model, applied date, and engine type in the APPLICATION
column.
^ Read the listed transmission model code(s) for that application in the TRANSMISSION MODEL
CODE column.
^ Read the actual AIPDN part number for that transmission in the TRANSMISSION PART
NUMBER column.
^ Read the proper TCM model code(s) for that application in the TCM MODEL CODE column.
^ Read the actual AIPDN part number for that TCM in the TCM PART NUMBER column.
For parts ordering information, refer to AIPDN Technical Bulletin AIPDN-TEC-LV1-96.

Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 98
Control Module: Locations
Transmission Control Unit And DLC Connector
Beneath left side of instrument panel.

Control Module: Description and Operation
PURPOSE
The Transmission Control Module (TCM), based on predetermined shifting characteristics and
lockup operating valve, provides optimum shifting control across the range of vehicle operating
conditions.
OPERATION
The following input signals are sent to the TCM: select lever position from the mode switch, running
mode from the power and winter switches, throttle opening from the throttle position sensor, vehicle
speed from the vehicle speed sensor, and engine rpm from the ECM. After receiving these signals,
the TCM determines vehicle running condition and sends output signals to each solenoid to control
shifting.
- When the TCC solenoid is engaged, the lockup mechanism operates. - Shift solenoids 2/3 and
1-2/3-4 select shift gear position. - The force motor controls line pressure to improve shift feel. -
When the TCM detects an abnormal signal, it causes the CHECK TRANS lamp on the instrument
panel to flash, alerting the driver to a
malfunction.
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Testing and Inspection
Wiper Control Module: Testing and Inspection
Fig. 60 Rear wiper controller
1. Disconnect wiper controller electrical connector.
2. Connect positive battery voltage to controller terminal No. 8 and negative to terminals No. 2 and
4, Fig. 60.
3. Connect terminal No. 1 and ground, then approximately 12 volts should be indicated.
4. Apply positive battery voltage to controller terminal No. 8 and negative to terminals No. 2, 6 and
7.
6. If voltage is not as specified, replace controller.

Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Testing and Inspection > Intermittent Wiper Relay
Wiper Relay: Testing and Inspection Intermittent Wiper Relay
Fig. 55 Front Intermittent Relay
1. Connect positive battery voltage to terminals No. 3 and 6, Fig. 55. 2. Connect negative to No. 1.
3. Ensure battery voltage is intermittent at terminal No. 2.
Isuzu Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Testing and Inspection > Intermittent Wiper Relay > Page 108
Wiper Relay: Testing and Inspection Rear Wiper Relay
Fig. 58 Rear Wiper Relay
1. Using suitable ohmmeter, ensure continuity exists between terminals No. 1 and 2, Fig. 58. 2.
Continuity should not exist between terminals No. 3 and 4. 3. Apply battery voltage between
terminals No. 5 and 6, then test continuity. 4. Continuity should not be indicated between terminals
1 and 2. 5. Continuity should exist between terminals 3 and 4. 6. If continuity is not as indicated,
replace relay.
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Description and Operation
Brake Fluid Level Sensor/Switch: Description and Operation
The standard master cylinder is equipped with a fluid level sensor located in the reservoir. This
sensor will activate the red ``Brake'' lamp if a low fluid condition is detected. Once the fluid level is
corrected the lamp will go out.
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair
Wheel Speed Sensor: Service and Repair
1. Raise and support vehicle.
2. Disconnect sensor harness connector.
3. Remove speed sensor retaining bolt, then sensor.
4. Reverse procedure to install, noting the following: a. Torque speed sensor retaining bolt to 18 ft.
lbs.
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications
Engine Temperature Sensor: Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
-18°C (0°F) ..........................................................................................................................................

.................................................................. 25K ohms -7°C (20°F) ......................................................
................................................................................................................................................... 13.5K
ohms 4°C (40°F) ..................................................................................................................................
.......................................................................... 7.5K ohms 20°C (68°F) ............................................
..............................................................................................................................................................
3.4K ohms 38°C (100°F) .....................................................................................................................
................................................................................... 1.8K ohms 70°C (160°F) .................................
..............................................................................................................................................................
........... 450 ohms 100°C (212°F) .........................................................................................................
............................................................................................... 185 ohms
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 122
Engine Temperature Sensor: Locations
ECT Sensor
In the L.H. coolant cross-over passage at the back.

Engine Temperature Sensor: Description and Operation
Engine Coolant Temperature Sensor
ECT Sensor
PURPOSE
Provides engine temperature information to the Engine Control Module (ECM).
OPERATION
The ECM supplies a 5V signal to the sensor and measures voltage variation. By measuring this
variation, the ECM measures coolant temperature. This input is a factor in calculations involving
most ECM controlled systems.
CONSTRUCTION
The coolant temperature sensor is a thermistor (a device whose resistance changes with
temperature) mounted in the engine cooling system. Low temperature produces high resistance
(100K ohms at -40°C / -40°F) while high temperature produces low resistance (70 ohms at 130°C /
266°F).
Engine Temperature Sensor: Testing and Inspection
ECT Sensor
For full testing information, Refer to Diagnostic Trouble Code Chart 14.
Engine Temperature Sensor: Service and Repair
Engine Coolant Sensor
REMOVAL
NOTE: Care must be taken when handling Engine Coolant Temperature (ECT) sensor. Damage to
the ECT sensor will affect proper operation of the fuel injection system.
- Negative battery cable. - Drain engine coolant system. - Intake manifold assembly. Refer to Fuel
Delivery and Air Induction. - Electrical connector - ECT sensor. Remove from rear of engine
coolant transfer tube.
INSTALLATION
- ECT sensor. Apply sealer or equivalent to threads only. - Tighten the ECT sensor to the specified
torque
Torque 30 N-m (22 lb-ft)
- ECT sensor connector - Intake manifold assembly - Negative battery cable. - Refill engine coolant
system.
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Temperature Sensor (Gauge): Locations
REAR OF ENGINE IN COOLANT MANIFOLD.

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Diagrams > Diagram Information and Instructions
Blower Motor Switch: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Information > Diagrams > Diagram Information and Instructions > Page 134

Blower Motor Switch: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Air Conditioner: Blower Control
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Blower Motor Switch: Initial Inspection and Diagnostic Overview
FAN CONTROL LEVER (FAN SWITCH)
1. Check for continuity between the terminals of the fan control lever.
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 157
Blower Motor Switch: Symptom Related Diagnostic Procedures

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature
Sensor / Switch: > SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction
Evaporator Temperature Sensor / Switch: All Technical Service Bulletins A/C Thermostat - Manual
Correction
BULLETIN NUMBER SB93-12-005
ISSUE DATE December 1993
GROUP AIR CONDITIONING
1993 A/C THERMOSTAT
(WORKSHOP MANUAL CORRECTION)
AFFECTED VEHICLES
1993 Trooper (UX), Rodeo (UC), Pickup (TF) and Amigo (TC) models equipped with air
conditioning.
SERVICE INFORMATION
The air conditioning electronic thermostat and thermostat removal procedures for affected vehicles
are incorrectly described in the Workshop Manuals:
Affected vehicles may be equipped with either of the following two different types of A/C electronic
thermostat:
BRACKET TYPE: The thermostat is built into a bracket, which can be removed without refrigerant
recovery and evaporator removal.
CLIP TYPE: The thermostat can only be removed after the refrigerant is recovered and the
evaporator is removed.
Sensor / Switch: > SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction > Page 167
This Service Bulletin contains corrected A/C thermostat descriptions and service procedures for
affected vehicles.
Sensor / Switch: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents
Evaporator Temperature Sensor / Switch: All Technical Service Bulletins A/C System - Poor
Cooling/Mist From Vents
ISSUE DATE July 1993
1993 RODEO (UC), PICKUP (TF) AND AMIGO (TC) A/C EVAPORATOR FREEZING UP
AFFECTED VEHICLES
1993 Rodeo (UC), Pickup (TF) and Amigo (TC) models equipped with air conditioning.
SERVICE INFORMATION
Some affected vehicles may experience one or more of the following A/C conditions:
^ Poor cooling after extended drive, then proper cooling after A/C has been turned off for 15 to 20
minutes.
^ Reduced airflow from dash vents.
^ Visible mist coming from dash vents.
The above conditions are caused by the evaporator freezing up due to incorrect positioning of the
A/C thermostat in the evaporator case. To eliminate the problem, install an A/C thermostat
relocation kit as described in this Service Bulletin.
SERVICE PROCEDURE
NOTE
Some affected vehicles have already had the thermostat relocated prior to delivery to dealers. On
these vehicles, a round blue sticker or white part number label has been affixed to the bottom of
the evaporator case. This indicates that the thermostat has already been relocated. Do not perform
this Service Procedure if a round blue sticker or white part number label is already affixed to the
bottom of the evaporator case.
Install the thermostat relocation kit (listed in "Parts Information" section of this Service Bulletin) as
follows:
NOTE:
Refrigerant evacuation/recovery is not necessary to perform this procedure.
1. Disconnect negative battery cable.
2. Remove glovebox as described in the appropriate Workshop Manual.
3. Remove rubber grommet from evaporator case. Carefully pull the thermostat probe wire from the
case, just enough to create a slight tension on the wire. Cut the probe wire as close as possible to
the case. See Figure 1.
Sensor / Switch: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents > Page 173
4. Thermosensor Removal (Figure 2):
a. Disconnect the thermosensor connector.
b. Remove thermosensor probe wire from the clips along the evaporator case.
c. Discard thermosensor.
5. Install new thermosensor (provided in the kit) to the evaporator case, where original
thermosensor was located. Connect thermosensor connector.
6. Insert plastic bracket (with probe) provided in kit into the existing hole at the side of the
evaporator case, as shown in Figure 3. Secure bracket to case, using screw provided in kit. Be
sure the bracket is properly aligned in the hole.
7. Route the thermosensor wire through the clips along the evaporator case (Figure 4). Store any
slack portion of thermosensor probe wire behind the resistor harness.
8. Reinstall glovebox as described in the appropriate Workshop Manual.

Sensor / Switch: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents > Page 174
9. Reconnect negative battery cable.
10. Start the engine. Depress the A/C switch and confirm compressor clutch engagement.
PARTS INFORMATION
Part No. Description
2-90050-346-0 A/C Thermostat Relocation Kit
FLAT RATE MANUAL UPDATE INFORMATION
Use the new labor operation.
NOTE:

Switch > Component Information > Technical Service Bulletins > Customer Interest: > 9312003 > Jul > 93 > A/C System -
Poor Cooling/Mist From Vents
Evaporator Temperature Sensor / Switch: Customer Interest A/C System - Poor Cooling/Mist From
Vents
AFFECTED VEHICLES
SERVICE INFORMATION
minutes.
SERVICE PROCEDURE
NOTE
follows:
NOTE:
Poor Cooling/Mist From Vents > Page 180

Poor Cooling/Mist From Vents > Page 181
PARTS INFORMATION
NOTE:

Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Temperature
Sensor / Switch: > SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction
Correction
1993 A/C THERMOSTAT
AFFECTED VEHICLES
conditioning.
SERVICE INFORMATION
thermostat:
affected vehicles.
Switch > Component Information > Technical Service Bulletins > Page 189
Picture 15
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Testing and Inspection > Dual Pressure Switch
Refrigerant Pressure Sensor / Switch: Testing and Inspection Dual Pressure Switch
DUAL PRESSURE SWITCH
1. Check for continuity between pressure switch side connector terminals.

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Testing and Inspection > Dual Pressure Switch > Page 194
Refrigerant Pressure Sensor / Switch: Testing and Inspection Triple Pressure Switch
TRIPLE PRESSURE SWITCH (Automatic Transmission)
1. Disconnect the connector and check for continuity between pressure switch side connector
terminal. 2. Reconnect the connector to activate the A/C switch, and check to see if there is
continuity between the chassis side connector terminals and the fan
operates.
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Fuel Gauge Sender: Locations
Fuel Gauge Tank Unit
Located on right side under vehicle.

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Headlamp Switch: Locations
Component ..........................................................................................................................................
................................................................ Photo No.
Combination Switch - Top left side of steering column

...................................................................................................................................................... 75
Dash Fuse Box - Left side of I/P , behind panel ..................................................................................

................................................................................ 63
Fuse/Relay Box - Right side of engine compartment, on inner fender panel

...................................................................................................................... 16
Headlight Relay - Right side of engine compartment, in fuse/relay box

............................................................................................................................. 17
Trailer Connector C315 (6-GRY) - Beneath vehicle. behind right rear corner of fuel tank
................................................................................................ 62
Upshift Relay - Behind right side of I/P, above kick panel

................................................................................................................................................. 90
Warning Buzzer Control Unit - Behind right side of I/P, above kick panel
........................................................................................................................ 89
C107 (2-GRY) - Behind left front side marker light

.............................................................................................................................................................
1
C109 (3-GRY) - Behind left side of radiator grille ................................................................................

............................................................................... 4
C113 (3-GRY) - Behind right side of radiator grille

.............................................................................................................................................................
2
C117 (2-GRY) - Behind right front side marker light

........................................................................................................................................................... 1
C201 (12-BLU) - Behind left side of I/P, above kick panel

................................................................................................................................................ 72
C205 (16-BLK) - Behind right side of I/P, above kick panel

.............................................................................................................................................. 88
C228 (20-WHT) - Below left side of I/P, at kick panel

...................................................................................................................................................... 66
C232 (16-BLK) - Behind left side of I/P, above kick panel

................................................................................................................................................ 71
C233 (16-WHT) - Behind left side of I/P, above kick panel

............................................................................................................................................... 71
C245 (13-WHT) - Behind left side of I/P, at bottom of steering column

............................................................................................................................ 81
C247 (2-BLK) - Below shift lever cover ...............................................................................................

............................................................................ 108
............................................................................ 109
C274 (14-BLK) (3.2L) - On rear of instrument cluster

....................................................................................................................................................... 76
C275 (12-WHT) (2.6L) - On rear of instrument cluster

...................................................................................................................................................... 76
C282 (2-WHT) - Center of I/P, behind heater and A/C control panel
................................................................................................................................ 84
C285 (2-WHT/BLU) - Center of I/P, behind heater and A/C control panel
....................................................................................................................... 84
................................................................................................................................ 84
C306 (14-WHT) - In floor, below right front seat

.............................................................................................................................................................
111
C406 (6-WHT) - Behind left taillight assembly .....................................................................................

........................................................................... 122
C408 (3-PIN) (without Rear Wiper) - Beneath vehicle, behind left side of rear bumper
.................................................................................................... 61
C408 (9-BLK) (with Rear Wiper) - Beneath vehicle, behind left side of rear bumper
....................................................................................................... 61
C411 (6-WHT) - Behind right taillight assembly

..............................................................................................................................................................
122
C416 (2-GRY) - Center of rear bumper, behind license plate holder

.................................................................................................................................. 62
G200 - Below left side of I/P, behind engine control module (ECM)
................................................................................................................................. 70
Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Component Information > Diagrams > Diagram Information and Instructions > Page 205

Headlamp Switch: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Headlamp Switch: Electrical Diagrams
Headlight Switch
Headlight Switch
Headlight Switch
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Service and Repair
Turn Signal Switch: Service and Repair
1. On models equipped with airbag system, refer to Technician Safety Information for system
disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove steering wheel
as outlined under Steering Wheel. 4. Remove screws securing upper and lower steering column
covers. Disconnect electrical connectors. 5. Remove windshield wiper/washer switch and/or
combination turn signal, headlight dimmer and hazard warning switch by removing retaining
screws.
6. Remove lock cylinder housing by removing snap ring and washer, followed by the attaching
bolts. 7. Reverse procedure to install. 8. On models equipped with airbag system, refer to
Technician Safety Information for system disarming and arming procedures.
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Sensor mounting bolt tighten to:
87 in lb (10 Nm)
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 236
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
R.H. side of engine block.

Page 237
Crankshaft Position Sensor: Description and Operation
PURPOSE
Provides information such as firing order and starting timing of each ignition coil.
CONSTRUCTION and OPERATION
The system uses a magnetic Crankshaft Position (CKP) sensor which protrudes into the block,
within approximately .050" of the crankshaft reluctor. The reluctor is a special wheel cast on the
crankshaft that has seven machined slots, six of which are equally spaced 60 ° apart. The seventh
slot is spaced 10 ° from one of the other slots. As the reluctor rotates with the crankshaft, the slots
change the magnetic field of the sensor, causing an induced voltage pulse.
By counting the time between pulses, the Ignition Control Module (ICM) can recognize the pulse of
the seventh slot (sync pulse). Based on this sync pulse, the module sends the reference signal to
the Engine Control Module (ECM) to calculate CKP (used to fire coils in correct sequence) and
engine speed.
Page 238
Crankshaft Position Sensor: Service and Repair
REMOVE
1. Disconnect battery ground cable.
Protection Shield
2. Remove exhaust and transfer protector.
3. Disconnect front propeller shaft joint.
Crank Angle Sensor / Crankshaft Position Sensor
4. Disconnect wiring connector at crank angle sensor.
5. Remove mounting nut and remove sensor.
REFIT
1. Lubricate O-ring on new sensor and fit to engine block.
2. Fit sensor mounting bolt and tighten to:
87 in lb (10 Nm)
3. Reconnect front propeller shaft joint and tighten to:
46 ft lb (63 Nm)
4. Refit protection shield and tighten bolts to:
27 ft lb (37 Nm)
5. Reconnect battery cable.

Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
-18°C (0°F) ..........................................................................................................................................

.................................................................. 25K ohms -7°C (20°F) ......................................................
................................................................................................................................................... 13.5K
ohms 4°C (40°F) ..................................................................................................................................
.......................................................................... 7.5K ohms 20°C (68°F) ............................................
..............................................................................................................................................................
3.4K ohms 38°C (100°F) .....................................................................................................................
................................................................................... 1.8K ohms 70°C (160°F) .................................
..............................................................................................................................................................
........... 450 ohms 100°C (212°F) .........................................................................................................
............................................................................................... 185 ohms
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications >
Page 242
ECT Sensor

Page 243
ECT Sensor
PURPOSE
OPERATION
CONSTRUCTION
266°F).
Page 244
ECT Sensor
Page 245
REMOVAL
INSTALLATION
torque
system.
Switches - Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] >
Component Information > Specifications
Intake Air Temperature Sensor: Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
20°F (-7°C) ..........................................................................................................................................

............................................................... 13.5K ohms 68°F (20°C) .....................................................
..................................................................................................................................................... 3.4K
ohms 100°F (38°C) ..............................................................................................................................
.......................................................................... 1.8K ohms
Component Information > Specifications > Page 249
Intake Air Temperature Sensor: Locations
IAT Sensor And MAP Sensor
On the intake collector.

Intake Air Temperature Sensor: Description and Operation
MAT Sensor
PURPOSE
Provides the Engine Control Module (ECM) with intake air temperature. The ECM uses this
information to determine air density.
OPERATION
The ECM supplies a 5V reference signal to the sensor and by measuring the voltage change can
determine the manifold air temperature.
Low temperature results in high resistance (100K ohms at -40°C / -40°F); high temperature results
in low resistance (70 ohms at 130°C / 266°F).
IAT sensor is also used to control spark timing and delays EGR when intake air is cold.
A failure in Intake Air Temperature (IAT) sensor circuit should set a Code 23.
CONSTRUCTION
The Intake Air Temperature (IAT) Sensor is a thermistor (resistor) whose resistance value varies in
relation to the temperature of air entering the engine.
Intake Air Temperature Sensor: Service and Repair
REMOVAL
- Negative battery cable. - Wiring connector - Disconnect connector from Intake Air Temperature
(Iat) sensor. - IAT sensor
INSTALLATION
- AT sensor. Apply sealer or equivalent to Threads only. - Tighten the IAT sensor to the specified
torque.
Torque 30 Nm (22 lb-ft)
- Wiring connector
Switches - Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor]
> Component Information > Specifications
Manifold Absolute Pressure Sensor: Specifications
Manifold Absolute Pressure (MAP) Sensor
Altitude (meters / feet) related to voltage:
Below 305 / 1000..................................................................................................................................

........................................................3.8 - 5.5V 305-610 / 1000-2000....................................................
.................................................................................................................................3.6 - 5.3V
914-1219 / 3000-4000..........................................................................................................................
.........................................................3.3 - 5.0V 1219-1524 / 4000-5000...............................................
..................................................................................................................................3.2 - 4.8V
1524-1829 / 5000-6000........................................................................................................................
.........................................................3.0 - 4.6V 2133-2438 / 7000-8000...............................................
..................................................................................................................................2.8 - 4.3V
2743-3048 / 9000-10,000.....................................................................................................................
.........................................................2.5 - 4.0V
> Component Information > Specifications > Page 255
Manifold Absolute Pressure Sensor: Locations

Manifold Absolute Pressure Sensor: Description and Operation
MAP Sensor
PURPOSE
Measures pressure in the intake manifold.
OPERATION
The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold
pressure which result from engine load and speed changes, and converts this to a voltage output.
A closed throttle on engine coast down would produce a relatively low MAP output, while a Wide
Open Throttle would produce a high output. MAP is the OPPOSITE of what would be measured on
a vacuum gage. When manifold pressure is high, vacuum is low. The MAP sensor is also used to
measure BAROMETRIC PRESSURE under contain conditions, which allows the ECM to
automatically adjust for different altitudes. The Engine Control Module (ECM) sends a 5 volts
reference signal to the MAP sensor. As the manifold pressure changes, the electrical resistance of
the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold
pressure. A higher pressure, low vacuum (high voltage) requires more fuel, while a lower pressure,
higher vacuum (low voltage) requires less fuel.
A failure in the MAP sensor circuit should set a DTC 33. See: Powertrain Management/Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Engine Control System/DTC 33
Manifold Absolute Pressure Sensor: Testing and Inspection
MAP Sensor Circuit

Chart C-1D MAP Sensor Output Voltage Check
Circuit Description
Manifold Absolute Pressure (MAP) sensor measures the changes in the intake MAP which result
from engine load (intake manifold vacuum) and revolution per minute changes; and converts these
into a voltage output. The Engine Control Module (ECM) sends a 5-volt reference voltage to the
MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring
the sensor output voltage, the ECM knows the MAP. A lower pressure (low voltage) output voltage
will be about 1 - 2 volts at idle. While higher pressure (high voltage) output voltage will be about 4 -
4.8 at Wide Open Throttle. The MAP sensor is also used, under certain conditions, to measure
BAROMETRIC PRESSURE, allowing the ECM to make adjustment for different altitudes. The ECM
uses the MAP sensor to control fuel delivery and ignition timing.
Test Description
Numbers below refer to circled numbers on the diagnostic chart. NOTE Be sure to use the same
Diagnostic Test Equipment for all measurements.
1. When comparing "Scan tool" readings to a known good vehicle, it is important to compare
vehicle that use a MAP sensor having the same color insert or having the same "Hot Stamped"
number.
2. Applying 34 kPa (10" hydragyrum) vacuum to the MAP sensor should cause the voltage to be
1.5-2.1 volts than the voltage at Step 1. Upon applying vacuum to the sensor, the change in
voltage should be instantaneous. A slow voltage change indicates a faulty sensor.
3. Check vacuum hose to sensor for leaking or restriction. Be sure that no other vacuum devices
are connected the MAP hose.
NOTE: Make sure electrical connector remains securely fastened.
4. Disconnect sensor from bracket and twist sensor by hand (only) to check for intermittent
connection. Output changes greater that .10 volt indicate a bad sensor.
Manifold Absolute Pressure Sensor: Service and Repair
MAP Sensor
- Battery negative cable. - Vacuum hose - Electrical connector - Attaching screws - Sensor
INSTALL OR CONNECT
- Sensor - Attaching screws - Electrical connector - Vacuum hose - Battery negative cable.
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > O2
Sensor Circuit - Manual Update
Oxygen Sensor: Technical Service Bulletins O2 Sensor Circuit - Manual Update
ISSUE DATE August 1993
GROUP ELECTRICAL
1993 RODEO (UC) OXYGEN SENSOR CIRCUIT (WORKSHOP MANUAL CORRECTION)
AFFECTED VEHICLES
1993 Rodeo (UC) models equipped with 3.2L V6 engine.
SERVICE INFORMATION
The oxygen sensor wiring circuit for affected vehicles is incorrectly shown in the Workshop Manual:
^ On 1993 Rodeo models with automatic transmission, the oxygen sensor heater element receives
power directly from fuse # 8.
^ On 1993 Rodeo models with manual transmission, the oxygen sensor heater element receives
power from fuse # 1 through the ECM main relay.
This circuit is shown correctly on pages 24 and 24-3 of the 1993 Rodeo Electrical Troubleshooting
Manual.
This Service Bulletin contains the starter system wiring diagram, with corrected oxygen sensor
circuit for the referenced Workshop Manual page.
Sensor Circuit - Manual Update > Page 265
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical
Specifications
Oxygen Sensor: Electrical Specifications
Normal voltage range ..........................................................................................................................
................................................................... 0.1 - 1.0V
Specifications > Page 268
Oxygen Sensor: Mechanical Specifications
Torque .................................................................................................................................................
......................................................... 45 Nm (33 ft lb)
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 269
Oxygen Sensor: Locations
O2 Sensor
In the exhaust pipe, near the transmission mode switch.

Oxygen Sensor: Description and Operation
HO2S
PURPOSE
The oxygen (O2) sensor measures the oxygen content of the exhaust. The ECM monitors the
sensor to maintain air/fuel mixture of 14.7 to 1.
OPERATION
The oxygen sensor monitors atmospheric air versus exhaust gas oxygen content to produce a
voltage output. This voltage ranges from approximately 0.1 volt (high oxygen-lean mixture) to 0.9
volt (low oxygen-rich mixture). By monitoring the oxygen sensor output voltage, the computer can
determine the amount of oxygen in the exhaust gas and adjust the air/fuel mixture accordingly, this
is known as "CLOSED LOOP" operation.
When the sensor is cold it is like an open circuit and produces no voltage below 600°F (315°C). An
open sensor circuit or cold sensor causes "OPEN LOOP" operation.
The heated oxygen sensor works in the same manner as the non-heated oxygen sensor. The
exception is that B+ is supplied to a heating unit that is part of the sensor itself. This heater
receives voltage from the generator charging circuit. The heater helps the ECM control the fuel
injection sooner for better fuel emissions. There are no malfunction Codes to detect if the heater
part of the sensor is working.
Oxygen Sensor: Testing and Inspection
HO2S Circuit
Chart C-1F HO2S Heater Circuit Inspection
Circuit Description
The generator charging circuit supplies battery voltage to the heater part of Heated Oxygen Sensor
(HO2S). The heater warms the HO2S to allow a
varying voltage to be produced by the HO2S more rapidly instead of waiting for the HO2S to
heat-up on its own.
Test Description
Number(s) below refer to circled number(s) on the diagnostic chart. The following test procedures
are for the heater part of the HO2S. No malfunction Diagnostic Trouble Codes (DTC) will be logged
if the heater fails to function properly.
1. This will verify that battery positive voltage is present for the heater.
2. This check will test the ground circuit to the heater.
3. This test the heater element resistance. Resistance will vary with the temperature of the sensor.
Normal resistance is between 3.5 - 14.3 ohms.
Diagnostic Aids
^ A poor or loose connection at the HO2S could result in a false DTC being set or the C2 heater
not functioning properly.
^ A shorted HO2S heater could cause a DTC 13 to set.

Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
O2 Sensor
Caution: ^
The Heated Oxygen Sensor (HO2S) uses a permanently attached pigtail and connector. This
pigtail should not be removed from the HO2S. Damage or removal of the pigtail or connector could
affect proper operation of the HO2S.
^ Take care when handling the HO2S. The in-line electrical connector and louver end must be kept
free of grease, dirt, or other contaminants. Also, avoid using cleaning solvents of any type. Do not
drop or roughly handle the HO2S.
- Battery negative cable. - HO2S wiring connector. - HO2S
Caution: ^
The HO2S may be difficult to remove when engine temperature is below 45° C (120° F).
^ Excessive force may damage threads in exhaust pipe.
INSTALL OR CONNECT
- HO2S
NOTE: ^
A special anti-seize compound is used on the HO2S threads. The compound consists of a liquid
graphite which will burn away, but the glass beads will remain, making the sensor easier to
remove.
^ New or service sensors will already have the compound applied to the threads. If a sensor is
removed from an engine and if for any reason it is to be reinstalled, the threads must have anti-
seize compound applied before reinstallation.
^ Apply anti-seize compound or equivalent to threads of oxygen sensor if necessary.
- Tighten the oxygen sensor to the specified torque.
- HO2S wiring connector. - Battery negative cable.

Oxygen Sensor (HO2S) > Page 275
Oxygen Sensor: Service and Repair Oxygen Sensor Life Indicator Light
OXYGEN SENSOR LIFE INDICATOR LIGHT (O2) RESET PROCEDURE
At 90,000 mile intervals, the O2 sensor lamp will illuminate. After replacing the sensor, perform the
following procedure to reset the lamp.
Maintainence Reminder Light Reset
- Remove instrument cluster.
- Remove masking tape from hole B.
- Remove screw from hole A and install into hole B.
- Apply new masking tape to hole A.
- Install instrument cluster.
NOTE: This procedure assumes that the sensor is being replaced for the first time (at 90,000
miles). For subsequent procedures (every 90,000 miles) the procedure will be reversed.
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications
Power Steering Pressure Switch: Specifications
Pressure ..............................................................................................................................................
..................................................... Switch Condition
Low pressure .......................................................................................................................................

........................................................................... open High pressure .................................................
........................................................................................................................................................
continuity
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications >
Page 279
Power Steering Pressure Switch: Locations
L.F. corner of engine compartment, in the pump.
Page 280
Power Steering Pressure Switch: Description and Operation
PURPOSE
Provides the ECM with power steering load information.
LOCATION
In the pressure line, near the radiator.
OPERATION
The Power Steering Pressure Switch tells ECM vehicle is in parking maneuver. ECM will
compensate for additional engine load by adjusting idle air control valve and switching OFF A/C
compressor when high pressures are detected.
Page 281
Power Steering Pressure Switch: Testing and Inspection
PSP Switch Circuit
Chart C-1E PSP Switch Circuit
Circuit Description
The Power Steering Pressure (PSP) Switch is normally open to ground, and GRN/YEL wire will be
near the battery positive voltage. Turning the steering wheel increases power steering oil pressure
and its load on an idling engine. The pressure switch will close before the load can cause an idle
problem. Closing the switch causes GRN/YEL wire to read less than I volt. The Engine Control
Module (ECM) will increase the idle air rate and disengage the air conditioning relay.
^ A pressure switch that will not close, or an open GRN/YEL wire, may cause the engine to stop,
when power steering loads are high. ^ A switch that will not open or a GRN/YEL wire shorted to
ground, may affect idle quality and will cause the air conditioning relay to be
Page 282
de-energized.
Test Description
1. Different makes of "Scan tools" may display the state of this switch in different ways. Refer to
"Scan too!" operator's manual to determine how this input is indicated.
2. Checks to determine if GRN/YEL wire is shorted to ground.
3. This should simulate a closed switch.

Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications >
Electrical Specifications
Throttle Position Sensor: Electrical Specifications
Throttle Position ...................................................................................................................................
...................................... Signal Voltage To ECM
At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Electrical Specifications > Page 287
Throttle Position Sensor: Mechanical Specifications
TPS sensor fixing screw
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page
288
Throttle Position Sensor: Locations
Idle Air Control (IAC) Valve
On the throttle chamber.

289
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
TPS
PURPOSE
Informs the ECM with throttle valve position information.
OPERATION
The Throttle Position Sensor (TPS) is a potentiometer connected to the throttle shaft on the throttle
body assembly. TPS electrical circuit consists of a 5 volt supply line and a ground line, both
provided by ECM. By monitoring voltage on this signal line, ECM calculates throttle position. As
throttle valve position is changed, output of TPS also changes. At closed throttle position, TPS
output is low (approximately .5 volt). At wide open throttle, output is high (approximately 4 volts).
A problem in any of the TPS circuits should set a diagnostic trouble code (DTC) 21. Once a DTC is
set, the ECM will use an artificial default value for TPS sensor. A high idle will result when DTC 21
is set.
290
Throttle Position Sensor: Testing and Inspection
A "Scan tool" displays throttle position in volts. Throttle position sensor (TPS) voltage should read
below 0.85 volts, with throttle closed and ignition "ON", or at idle. Voltage should increase at a
steady rate as throttle is moved toward wide open throttle. The Engine Control Module ( ECM) has
the ability to auto-zero the TPS voltage if it is below about 0.85 volts. This means that any voltage
less than 0.85 volts will be determined by the ECM to be 0% throttle.
Some "Scan tools" have the ability to read the throttle angle and should read 0%, when the throttle
is closed. A failure in the TPS or circuit should set a DTC 21. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Engine Control System/DTC 21
291
Throttle Position Sensor: Adjustments
Throttle Position Sensor (TPS)
TPS is an auto zeroing type and cannot be adjusted.
^ Use a "Scan tool" to check TP sensor output voltage with throttle closed, should be under 0.85
volts. If over 0.85 volts, check for binding
throttle shaft, or TP sensor lever. If all OK, replace TP sensor.

292
Throttle Position Sensor: Service and Repair
TP Sensor
- Battery negative cable. - Throttle Position (TP) sensor wiring connector - TP sensor fixing screw -
TP sensor
INSTALL OR CONNECT
- TP sensor - TP sensor fixing screw - Tighten the fixing screw to the specified Torque.
Torque 2 Nm (18 lb-in)
- Use a "Scan tool" to check TP sensor output voltage with throttle closed, should be under 0.85
volts. If over 0.85 volts, check for binding throttle
shaft, or TP sensor lever. If all OK, replace TP sensor.
- TP sensor wiring connector

Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service
Bulletins > Vehicle Speed Sensor - Manual Correction
Vehicle Speed Sensor: Technical Service Bulletins Vehicle Speed Sensor - Manual Correction
GROUP ELECTRICAL
RODEO (UC) VEHICLE SPEED SENSOR SERVICE PROCEDURES (WORKSHOP MANUAL

CORRECTION)
AFFECTED VEHICLES
SERVICE INFORMATION
Removal, inspection and installation procedures for the vehicle speed sensor are missing from the
Workshop Manual:
This Service Bulletin contains vehicle speed sensor service procedures for the referenced
Workshop Manual.
Bulletins > Vehicle Speed Sensor - Manual Correction > Page 297
Bulletins > Page 298
Vehicle Speed Sensor: Locations
Picture 54
On R.H. side of transmission tailhousing.

Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Information and Instructions > Page 301
Vehicle Speed Sensor: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS
Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse
FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair

Vehicle Speed Sensor

Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 322
Vehicle Speed Sensor: Description and Operation
PURPOSE
Provides the Engine Control Module (ECM) with vehicle speed information.
OPERATION
The ECM applies and monitors a 12V signal to the sensor. When the drive wheels are turning, the
sensor alternately grounds the circuit, creating a pulsing action. The ECM calculates vehicle speed
based on the time between pulses. This sensor is used to help control the operation of the idle air
control system
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical
Specifications
At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 329

TPS
PURPOSE
OPERATION
is set.

TP Sensor
TP sensor
INSTALL OR CONNECT

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
87 in lb (10 Nm)
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 338

PURPOSE
engine speed.
REMOVE

Protection Shield
REFIT
87 in lb (10 Nm)
46 ft lb (63 Nm)
27 ft lb (37 Nm)

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Airbag - On/Off Switch Kit Availability
Air Bag Deactivation Switch: Technical Service Bulletins Airbag - On/Off Switch Kit Availability
BULLETIN NUMBER: SB98-04-L009
ISSUE DATE: NOVEMBER 1998
GROUP: ELECTRICAL
ISUZU DEALER ADVISORY: AVAILABILITY OF AIRBAG ON-OFF SWITCH KITS (SUPERSEDES

SB98-04-L003)
AFFECTED VEHICLES
All Isuzu models equipped with driver and/or passenger airbags.
SERVICE INFORMATION Genuine Isuzu Air Bag On-Off Switch Kits are now available from
AIPDN.
On November 18, 1997, the National Highway Traffic Safety Administration (NHTSA) issued a new
regulation, published in the November 21, 1997 Federal Register, allowing motor vehicle owners to
have airbag on-off switches installed in their vehicles under certain limited conditions. Under the
new regulation, vehicle owners may obtain written authorization from NHTSA to have retrofit driver
and/or passenger-side airbag on-off switches installed in their vehicles only if they fall into one or
more of the following categories of people at risk:
- Those who cannot avoid placing a rear-facing infant seat in the front passenger seat.
- Those who have an unusual medical condition that place them at specific risk.
- Those drivers who cannot adjust their seating position to keep back approximately 10 inches from
the steering wheel.
- Those who cannot avoid situations - such as a car pool - that require a child 12 years or under to
ride in the front seat.
Vehicle owners who are interested in learning about airbag on-off switches may contact NHTSA's
toll-free Hotline at 1-800-424-9393 or browse their web site at http://www.nhtsa.dot.gov. NHTSA will
provide the vehicle owner with an information brochure Air Bags & On-Off Switches: Information for
an Informed Decision and the accompanying form Request for Air Bag On-Off Switch. If after
reading the brochure, a vehicle owner decides to seek an authorization letter from NHTSA, he or
she must fill out the request form and mail it to NHTSA. If NHTSA approves the request, NHTSA
will then send the owner a letter authorizing dealers or other repair outlets to install an on-off switch
in his or her vehicle. (Remember that each on-off switch requires a separate authorization letter
from NHTSA.).
As a final matter, we remind you that the new regulation does not require dealers to install on~off
switches under any circumstances; it simply authorizes dealers to take such actions if the customer
has a specific authorization letter from NHTSA. Dealers must make their own decisions.
PARTS INFORMATION
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Airbag - On/Off Switch Kit Availability > Page 346
Refer to the included reference chart for detailed information concerning Isuzu's Air Bag On-Off
Switch Kits, including the component parts, the installation instruction sheet, and the vehicle
Owner's Manual insert.
Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: >
9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position
Neutral Safety Switch: All Technical Service Bulletins A/T Mode Switch - No Crank In Neutral
Position
ISSUE DATE June 1993
GROUP TRANSMISSION
RODEO (UC) AND TROOPER (UX) NO START IN NEUTRAL
AFFECTED VEHICLES
1991-93 Rodeo (UC) and 1992-93 Trooper (UX) models equipped with V6 engine and automatic
transmission before the following VINS:
^ VIN P4310980 Rodeo 2-wheel drive
^ VIN P7906876 Trooper
SERVICE INFORMATION
Some affected vehicles may experience a "no start" (no crank) condition when the A/T selector
lever is in the neutral position, caused by A/T mode switch failure. Follow the diagnosis procedure
in this Service Bulletin to determine if the mode switch requires replacement.
If mode switch replacement is necessary, install the mode switch listed in the "Parts Information"
section of this Bulletin.
SERVICE PROCEDURE
NOTE: Refer to the appropriate Electrical Troubleshooting Manual for connector number
references.
Check mode switch operation as follows:
1. Disconnect the starter solenoid connector (C130 on Trooper; C112 on Rodeo).
2. On 3.2L V6 models, remove the air cleaner assembly.

9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position > Page 356
3. Disconnect the mode switch connector (C113 on Trooper; C139 on '91-92 Rodeo; C135 on '93
Rodeo). See Figure 1.
4. On the mode switch side of the connector, install an ohmmeter between the red wire (violet wire
on '91 models) and the yellow wire (Figure 2).
5. a. If the ohmmeter reads continuity with the transmission selector lever in any other position
other than "P" (Park) or "N" (Neutral), the mode switch requires adjustment. Adjust mode switch as
described in Step 12 of this Service Procedure, then recheck mode switch operation starting from
Step 3.
After adjusting the mode switch, if the above check still results in continuity with the lever in any
other position other than "P" or "N", replace the mode switch (see "Parts Information" section of this
Service Bulletin) as described in the appropriate Workshop Manual. Then follow the mode switch
adjustment procedure described in Step 12.
b. If the ohmmeter reads continuity with the transmission selector lever in "P" or "N", but the engine
still does not start with the lever in "N", continue with this diagnosis procedure.
6. Remove the ohmmeter.

7.a. Check mode switch circuit from the starter switch by connecting a voltmeter between the mode
switch connector blue/black wire (white/green wire on '91-92 Rodeo) on the harness side, and
ground (Figure 3).
b. Turn the ignition key to "START" and note voltmeter reading.
8.a. If voltmeter reading is 0 volts, check the circuit from main fuse 1 to the mode switch connector.
b. If voltmeter reading is 12 volts, check the ground circuit from the mode switch connector to
ground (on Trooper LS models, anti-theft controller ground). Repair circuit as required.
9. Reconnect mode switch connector.
10. Reconnect starter solenoid connector.
11. On 3.2L V6 models, reinstall air cleaner assembly.
12. Mode Switch Adjustment Procedure (Figure 4)
a. Place gear selector lever in "N".
b. Under the vehicle, remove A/T linkage from the mode switch.
c. Remove mode switch cover.
d. Loosen the two 6 mm screws in the mode switch.
e. Rotate the mode switch until the slot in the mode switch aligns with the selector shaft bushing,
and insert a 3/32" (2.4 mm) drill bit or punch into the slot.
f. Tighten the screws to 113 in.lbs. Remove the drill bit.

g. Reinstall mode switch cover.
h. Reinstall gear selector lever.
PARTS INFORMATION
8-96017-178-0 Mode Switch (Trooper UX)
8-96017-197-0 Mode Switch (Rodeo)
Use the revised labor operation. See illustration.

> Component Information > Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 9305011 > Jun >
93 > A/T Mode Switch - No Crank In Neutral Position
Neutral Safety Switch: Customer Interest A/T Mode Switch - No Crank In Neutral Position
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
references.

93 > A/T Mode Switch - No Crank In Neutral Position > Page 365
Step 3.

ground (Figure 3).

PARTS INFORMATION

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications
Pressure ..............................................................................................................................................
Low pressure .......................................................................................................................................

........................................................................................................................................................
continuity
Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications > Page 374

PURPOSE
LOCATION
OPERATION
PSP Switch Circuit
Circuit Description
de-energized.
Test Description

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Barometric Pressure Sensor, A/T > Component Information > Locations
Barometric Pressure Sensor: Locations
Right rear corner of engine compartment.

Switches - A/T > Downshift Switch, A/T > Component Information > Locations
Downshift Switch: Locations
Beneath dash, near accelerator pedal.

Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
PURPOSE
Wen switched ON by the driver, this switch tells the TCM to operate the transmission in power
mode. When the switch is OFF, the transmission operates in economy mode.
OPERATION
When in power mode, the TCM delays upshifts, resulting in more powerful acceleration.
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
Transmission Temperature Sensor/Switch: Specifications
APPROX. RESISTANCE
@ -40°F (-40°C) ..................................................................................................................................

..................................................... 672 K ohms @ 32°F (0°C) .............................................................
................................................................................................................................. 65 K ohms @
68°F (20°C) .........................................................................................................................................
................................................... 25 K ohms @ 176°F (80°C) .............................................................
............................................................................................................................ 2.5 K ohms @
248°F (120°C) .....................................................................................................................................
..................................................... 780 ohms @ 302°F (150°C) ..........................................................
................................................................................................................................ 370 ohms
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 392
Transmission Temperature Sensor/Switch: Locations
Transmission adapter case.

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Front Wiper Switch
Wiper Switch: Testing and Inspection Front Wiper Switch
Fig. 54 Front Wiper Switch
Check continuity between terminals as outlined in Fig. 54.

Isuzu Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Front Wiper Switch > Page 398
Wiper Switch: Testing and Inspection Rear Wiper Switch
Wiper And Washer Switch
Rear Wiper And Washer Switch Inspection
Check for continuity between switch connector terminals.

Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Front End
Alignment - Inspection (Manual Revision)
Alignment: Technical Service Bulletins Front End Alignment - Inspection (Manual Revision)
GROUP: SUSPENSION
1992-98 TROOPER (UX), 1991-97 RODEO (UC), 1998 RODEO (UE) FRONT END ALIGNMENT
INSPECTION (Workshop Manual Revision)
AFFECTED VEHICLES
1992-98 Trooper (UX), 1991-97 Rodeo (UC), 1998 Rodeo (UE) models.
SERVICE INFORMATION
Alignment - Inspection (Manual Revision) > Page 404
The inspection procedure contained in Section 3A - Front End Alignment (1992-97 Trooper,
1991-97 Rodeo) and in Section 2A - Power Assisted Steering System (1998 Trooper and 1998
Rodeo) of the listed Workshop Manuals, has been revised.
The front end inspection procedure has been revised to include steps to ensure that the vehicle is
in an unladen condition (no passengers no loading) and that the spare tire is installed in its normal
position.
This Service Bulletin contains the revised pages to the referenced Workshop Manuals. Revisions to
the affected pages are shown. Attach the enclosed pages to the referenced Workshop Manual
pages.
Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment
Alignment: Specifications Front Wheel Alignment
Caster Angle, Degrees:
Limits ...................................................................................................................................................
.......................................... +1 7/12 to +3 1/12 Desired .......................................................................
........................................................................................................................................ +2 1/3
Camber Angle, Degrees:
Limits ...................................................................................................................................................
................................................... -1/2 to +1 1/2 Desired ......................................................................
........................................................................................................................................... + 1/2
Toe-In, Inch [01] ..................................................................................................................................

.................................................................... 0 to +.16 King Pin Inclination, Degrees ..........................
..............................................................................................................................................................
.... 10 Knuckle Angle At Full Lock, Degrees:
Inside ...................................................................................................................................................
.................................................................. [02] Outside ......................................................................
............................................................................................................................................ [03]
[01] -- Toe-in (+); toe-out (-). [02] -- With 10.5R tires, 32 degrees; less 10.5 tires, 35 degrees. [03] --
With 10.5R tires, 29 degrees; less 10.5 tires, 33 degrees.
Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment >
Page 413
Alignment: Specifications Rear Wheel Alignment
This model has a solid rear axle. No specifications exist for Camber or Toe-in.
Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension
Alignment: Service and Repair Front Suspension
Caster & Camber
Fig. 1 Caster angle adjustment
Fig. 2 Camber angle adjustment
Caster angle can be adjusted with caster shims installed in position between the chassis frame and
the fulcrum pins, Fig. 1. Camber angle can be adjusted with the shims installed in position between
the chassis frame and the fulcrum pins, Fig. 2.
Toe-In
To adjust toe-in angle, loosen locknut on the outer track rod and turn outer track rod with the same
degree as right and left, Fig. 3.
Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension >
Page 416
Alignment: Service and Repair Trim Height
Trim Height Inspection Procedure
Before making any wheel alignment adjustments, inspect the following:
1. Tires for proper inflation pressure. 2. Front wheel bearing for proper adjustment. 3. Ball joints, tie
rod ends and relay rods for excessive looseness. 4. Wheels and tires for run out. 5. Vehicle trim
height. If not within specifications, trim height must be corrected before adjusting caster. 6. Steering
gear for looseness at frame. 7. Shock absorbers for leaks or any noticeable noise. 8. Control arms
or stabilizer bar attachment for looseness.
Isuzu Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Front Suspension >
Page 417
Alignment: Service and Repair Vehicle Ride Height
Vehicle height is adjusted by an adjusting bolt on the control arms. Before adjusting trim height,
check tire pressure and ensure vehicle is on level ground.
Fig. 5 Ride height measurement points. 4WD models
1. Measure vehicle ride height as shown in Fig. 5. 2. Subtract measurement (A) from measurement
(B) to find vehicle ride height specification. 3. Turn adjustment bolt as necessary. Dimension (Z)
should be 4.96 inches.
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Locations
Fuel Pressure Test Port: Locations
Component Locations
On Fuel Rail at back of engine. N4 in Figure.

Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Locations > Page 423
Fuel Pressure Test Port: Description and Operation
PURPOSE
Allows a Fuel gauge to be connected for monitoring the fuel pressure in the Fuel Rail .
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Specifications
Air/Fuel Mixture: Specifications
ECM controlled, not adjustable

Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Specifications > Page 427
Air/Fuel Mixture: Adjustments
The air/fuel mixture is ECM controlled and there is no provision for adjustment. Refer to
COMPUTERS AND CONTROL SYSTEMS.
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
ECM controlled, not adjustable.

Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Idle Speed: Adjustments
The idle speed is Engine Control Module (ECM) controlled and there is no provision for adjustment.
Refer to Computers and Control Systems/Testing and Inspection if there is a problem with the idle
speed.
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner
Filter <--> [Air Filter Element] > Component Information > Description and Operation
Air Cleaner Filter: Description and Operation
Air Filter
PURPOSE
Filters dirt from intake air.
OPERATION
Particulates in the incoming air are trapped by the filter. the clean air then flows to the throttle
chamber.
CONSTRUCTION
It is a pleated, fiberous, disposable element. Service or cleaning is not required. Replace at

recommended intervals or sooner if dirty.
Filter <--> [Air Filter Element] > Component Information > Description and Operation > Page 436
Air Cleaner Filter: Testing and Inspection
Remove Air Cleaner Filter from air cleaner and visually inspect.
Check the Air Cleaner Filter for damage or dust clogging. Replace if it is damaged, oil saturated, or
if scheduled maintenance interval has been reached or clean if it is clogged.
Air Cleaner Filter: Service and Repair
Air Cleaner Assembly
REMOVAL
1. Air hose 2. Air cleaner cover 3. Air Cleaner Filter

CLEANING
Hit the Air Cleaner filter gently with care not to damage the paper filter, or clean the element by
blowing with compressed air of about 49kPa (71 psi) from the clean side if it is extremely dirty.
INSTALLATION
1. Air Cleaner filter 2. Air cleaner cover
^ Meet the cover to the body completely, then clamp it with the clip.
3. Air cleaner hose

Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: Adhere to the following procedures any time the fuel system is being worked on in
order to reduce the risk of fire and personal injury:
- Keep a dry chemical (Class B) fire extinguisher near the work area.
- Place a "CAUTION FLAMMABLE" sign in the work area.
- Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away.
- Wear eye protection.
- Use caution when working near the catalytic converter to prevent the possibility of burns or fire.
(The temperatures within the converter can exceed 537 degrees C (1000 degrees F).)
- Relieve the fuel system pressure prior to disconnecting fuel system components.
- Disconnect the negative battery cable except for tests where battery voltage is required.
- Use a suitable container to store or catch fuel.
- Do not replace fuel pipe with fuel hose.
- Plug all disconnected fuel line fittings and hoses.
- After making any fuel system repairs ALWAYS inspect for fuel leaks.
- Replace all pipes with the same pipe and fittings that were removed.
Do not reuse "O" rings. Always replace.
- Do not attempt repairs on the fuel system until you have read the instructions and checked the
pictures relating to that repair.
- Adhere to all Notices and Cautions.
NOTE: If available, use system bleed valve (schrader) to relieve pressure.
NYLON FUEL PIPE CAUTIONS: In order to reduce the risk of fire and personal injury observe the
following items:
- Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not
attempt to repair the sections of the nylon fuel pipes
- Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to
the nylon pipes may result in a fuel leak.
- Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never
expose the vehicle to temperatures higher than 115° C (239°F) for more than one hour, or more
than 90°C (194°F) for any extended period.
- Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings.
This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation,
the O-rings located in the female connector will swell and may prevent proper reconnection if not
lubricated.)
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 442
Fuel Pressure Release: Service and Repair
To reduce the risk of fire and personal injury, It is necessary to relieve the fuel system pressure
before servicing the fuel system. Unless this procedure is followed before servicing fuel lines and
connections, fuel spray could occur.
When repair to the fuel system has been completed, Start engine and check all connections that
were loosened for possible leaks.
1. Remove fuel cap 2. Remove fuel pump relay from underhood relay center. 3. Start engine and
allow to stall. 4. Crank engine for additional 30 seconds. 5. Remove negative battery cable.
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Firing Order: Specifications
Firing Order: 1 2 3 4 5 6
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Number One Cylinder: Locations
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil
Accumulation
Ignition Cable: Customer Interest Spark Plug Tube - Oil Accumulation
ISSUE DATE: SEPTEMBER 1996
GROUP: ENGINE
1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 6VD1-V SOHC SPARK PLUG TUBE OIL
ACCUMULATION
AFFECTED VEHICLES
1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 6VD1-V SOHC engine.
SERVICE INFORMATION
Some affected vehicles may experience oil accumulation in the spark plug tubes due to oil seepage
at the spark plug tube-to-cylinder head interface.
To seal off the seepage, replace the original spark plug wire set with a new, improved spark plug
wire set (see Parts Information section) using the procedure described in this Service Bulletin. The
new spark plug wire set has an improved bushing design that controls oil seepage at the spark plug
tube-to-cylinder interface.
SERVICE PROCEDURE
Replace the original spark plug wire set with the new, improved spark plug wire set (see Parts
Information section) in accordance with service procedures in appropriate Workshop Manual. For
Trooper models, refer to Section CD4 of appropriate Trooper (UX) Workshop Manual; for Rodeo
models, refer to Section 6D4A of appropriate Rodeo (UC) Workshop Manual.
PARTS INFORMATION
Part No. Description Quantity Required
8-97163-999-0 High Tension 4
Cable Kit (UX) (spark plug wire set)
8-97164-006-0 High Tension 1
Cable Kit (UC) (spark plug wire set)
Use published Flat Rate Manual labor operation number 040104 for replacement of spark plug wire
set.
Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 >
Spark Plug Tube - Oil Seepage
Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Seepage
ISSUE DATE: JUNE 1997
GROUP: ENGINE
1992-95 TROOPER (UX) AND 1993-95.5 RODEO (UC) 3.2L V6 SOHC ENGINE SPARK PLUG
TUBE OIL ACCUMULATION
AFFECTED VEHICLES
1992-95 Trooper (UX) and 1993-95.5 Rodeo (UC) models equipped with 3.2L V6 SOHC engine.
SERVICE PROCEDURE
When servicing affected vehicles experiencing oil accumulation in the spark plug tubes due to oil
seepage at the spark plug tube-to-cylinder head interface, be sure to refer only to Service Bulletin
SB96-01-L005, issued 9/96.
The authorized repair for affected vehicles experiencing this condition, is to replace the original
spark plug wire set with a new type wire set which features an improved bushing designed to
control oil seepage at the spark plug tube-to-cylinder head interface. SB96-01-L005 describes this
authorized repair.
Do not refer to Service Bulletin SB96-01-L004, issued 4/96, to repair this condition. It is not the
authorized repair. SB96-01-L004 is strictly intended to provide detailed service and warranty
information when spark plug tube replacement is required.
Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB96-01-L005 > Sep > 96 >
Spark Plug Tube - Oil Accumulation
Ignition Cable: All Technical Service Bulletins Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 >
Spark Plug Tube - Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
Information > Technical Service Bulletins > Page 472
Ignition Cable: Specifications
Ignition Wire Resistance
No.1 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.2 .....................................................................................................................................................
................................................ 5.7 - 13.1 K Ohms
No.3 .....................................................................................................................................................
................................................ 6.2 - 14.4 K Ohms
No.4 .....................................................................................................................................................
................................................ 5.8 - 13.3 K Ohms
No.5 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.6 .....................................................................................................................................................
................................................ 6.9 - 16.0 K Ohms
Ignition Cable: Description and Operation
Ignition Wire
PURPOSE
Conduct high voltage from the ignition coil to spark plugs.
CONSTRUCTION
The ignition wires have an internal resistance to suppress radio static and to eliminate static that
may interfere with sensitive computer components.
Ignition Cable: Testing and Inspection
Using an ohm meter, check the resistance between ignition wire terminal ends.
Cable # ................................................................................................................................................
.............................................................. x 1000 ohms
1 ...........................................................................................................................................................
................................................................... 6.4 - 14.9 2 ......................................................................
........................................................................................................................................................ 5.7
- 13.1 3 ................................................................................................................................................
.............................................................................. 6.2 - 14.4 4 ...........................................................
..............................................................................................................................................................
..... 5.8 - 13.3 5 ....................................................................................................................................
.......................................................................................... 6.4 - 14.9 6 ...............................................
..............................................................................................................................................................
................. 6.9 - 16.0
Ignition Cable: Service and Repair
Remove wires.
Spark Plug Wire Index
Be sure to refit to correct terminal.
NOTE: Do not cross, twist or pull spark plug wires.

Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil
Accumulation
Spark Plug: Customer Interest Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L005 > Sep > 96 >
Spark Plug Tube - Oil Accumulation
Spark Plug: All Technical Service Bulletins Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 >
Spark Plug Tube - Replacement Procedure
Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement Procedure
ISSUE DATE: APRIL 1996
GROUP: ENGINE
TROOPER (UX) AND RODEO (UC) 6VD1 SOHC SPARK PLUG TUBE REPLACEMENT
(Supersedes SB96-01-L001, to include sublet allowance information)
APPLICABLE VEHICLES
Trooper (UX) and Rodeo (UC) models equipped with 6VD1 SOHC engine.
SERVICE INFORMATION
If a spark plug tube (cylinder head tube) must be replaced, use the following procedure:
DISASSEMBLY
1. Spark Plug Tube
^ Remove spark plug tube using Kent-Moore tool J-41730 and slide hammer J-2619-01 (Figure 1A
and 1B). Leave spark plug contact.
CLEAN
^ Spark plug tube joining area. Carefully remove all varnish, soot, and old adhesive. Do not use
motorized wire brush for cleaning.
REASSEMBLY
1. Spark Plug Tube
^ Apply LOCTITE 290, or equivalent, to outer edge of spark plug tube (Figure 1C).
Spark Plug Tube - Replacement Procedure > Page 494
^ Install new spark plug tube, using Kent-Moore tool J-41730 and plastic-faced hammer (Figure 2).
^ Measure spark plug tube height (Figure 3).
Spark Plug Tube Height: 64 mm +/- 0.5 mm 2.52 in +/- .02 in

Spark Plug Tube - Replacement Procedure > Page 495
Use the following new labor operation:
Use Sublet Code B8 ($8.40) for Loctite 290 reimbursement. Dealers are allowed to claim one 8
milliliter bottle of Loctite 290 per VIN. This sublet code does not require dealer or Zone Service &
Parts Manager authorization.
Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 >
Spark Plug Tube - Replacement
Spark Plug: All Technical Service Bulletins Spark Plug Tube - Replacement
ISSUE DATE AUGUST 1995
GROUP ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
and 1B). Leave spark plug intact.
CLEAN
REASSEMBLY
1. Spark Plug Tube
Spark Plug Tube - Replacement > Page 500
Spark Plug Tube - Replacement > Page 501
^ Measure spark plug tube height (Figure 3). Spark Plug Tube Height: 65 mm +/- 0.5 mm
(2.56 in. +/- .02 in).
Use the new labor operation as shown.

Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark
Plug Tube - Replacement Procedure
GROUP: ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
Plug Tube - Replacement Procedure > Page 507

Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark
Plug Tube - Replacement
GROUP ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
Plug Tube - Replacement > Page 513
(2.56 in. +/- .02 in).

Information > Specifications > Electrical Specifications
Spark Plug: Electrical Specifications
Insulation Resistance ..........................................................................................................................

..................................................... 50 Mohms or more
Information > Specifications > Electrical Specifications > Page 517
Spark Plug: Mechanical Specifications
Spark plug gap ....................................................................................................................................

.................................. 0.040 - 0.043 in (1.0 - 1.1 mm)
Spark plug torque ................................................................................................................................

......................................................... 13 ft lb (18 Nm)
Spark Plug: Description and Operation
Spark Plug Cutaway View

PURPOSE
Spark plugs allow high-voltage secondary current to arc across a small air gap to ignite the air/fuel
mixture in the combustion chamber.
Spark Plug Temperature
HEAT RANGE
The temperature of the spark plug is determined by the length of the insulator and the size of the
heatsink area. The longer the insulator, the smaller the heatsink area will be. This causes the spark
plug to be hotter.
The heat range of the plug is determined by its ability to dissipate heat created during combustion.
If too cold a plug is used, the possibility of fouling is increased. A plug that is too hot can cause
preignition. Hotter plugs tend to burn cleaner with less deposit build-up. They can be used for
stop-start city driving, but not for extended high speed or load conditions as engine damage can
occur.
Spark Plug: Testing and Inspection
INSPECTION
- Check the electrodes and insulators for cracks. Replace if faulty.
- Check the electrodes for wear and replace as necessary.
- Check the gaskets for damage and replace as necessary.
- Check insulation resistance with an ohmmeter. Replace if defective. SPARK PLUG INSULATION
RESISTANCE
50 M ohms
- Check spark plug gap. Adjust or replace as necessary. SPARK PLUG ELECTRODE GAP
1.05 mm (0.040 in)
- If spark plug fouling is excessive, check fuel and electrical systems for possible causes. If those
systems are normal, install spark plugs of a higher heat range.
- If burning of the electrodes or insulator is considerable, install spark plugs of a lower heat range.
SOOTY SPARK PLUGS
If the electrodes and insulators are fouled with carbon or oil, the engine will operate efficiently.
There are a number of possible causes: -
Rich fuel mixture.
- Retarded ignition timeing.
- Excessive engine wear (oil in cylinders).
- Incorrect plug gap.
BLISTERED OR SCORCHED SPARK PLUGS
This condition is caused by excessive temperature at the spark plug. Common causes are: -
Lean fuel mixture.
- Advanced ignition timing.
- Incorrect plug heat range.

Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > System Diagnosis
Compression Check: Testing and Inspection
1. Start and warm engine to operating temperature. 2. Remove all spark plugs and apply a few
drops of engine oil into spark plug holes. 3. Relieve fuel system pressure as outlined under
Precautions. 4. Disable ignition system, by removing ignition fuse. 5. Connect a tachometer and
crank engine, ensure cranking speed is 300 RPM or higher. 6. Install compression gauge, then
crank engine with throttle wide open. 7. Minimum pressure should be 128 psi.
Isuzu Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 > Sep > 00
> Engine Valve Train - Ticking Noise
Technical Service Bulletin # SB00-01-S009 Date: 000901
Engine Valve Train - Ticking Noise
BULLETIN NUMBER: SB00-01-S009
GROUP: ENGINE
TICKING SOUND FROM HYDRAULIC VALVETRAIN (Supersedes SB00-01-S002)
NOTE:
This service bulletin is being revised to update parts information.
AFFECTED VEHICLES
Some 1997 and earlier Trooper (UX) and Rodeo (UC) V6 models
SERVICE INFORMATION
Condition: The above affected vehicles may exhibit a condition of ticking sounds coming from the
valvetrain during normal operation.
Possible Cause: One or more hydraulic lash adjusters do not fully extend due to varnish build-up
inside. This condition results from exceeding the required oil and filter change intervals. Severe
driving conditions require more frequent oil and filter changes. (Refer to appropriate Owner's
Manual or Workshop Manual for details.)
Correction: A typical repair for the condition may involve the replacement of the affected rocker
arm(s), and rocker shaft(s). However, follow the information in this bulletin to perform an oil/filter
change using 0W-30 Mobil 1 synthetic engine oil, prior to replacing any valvetrain component.
NOTE:
Although the current recommended engine oil for these engines is 10W-30 API SJ, the 0W-30
synthetic engine oil allows air in the hydraulic lash adjusters to bleed out quickly and removes the
varnish that is preventing hydraulic lash adjuster piston travel.
PARTS INFORMATION
WARRANTY CLAIM INFORMATION
None: This is not a warranty matter (see POSSIBLE CAUSE).

> Engine Valve Train - Ticking Noise > Page 531
Service Procedure
1. Drain the engine oil, replace the oil filter with a Genuine Isuzu oil filter, and refill the crankcase
with 0W-30 Mobil 1 synthetic engine oil.
2. With the engine warm, run it at 2,500 rpm for 30 minutes.
^ If the ticking noise goes away, return the vehicle to the customer.
^ If the ticking noise persists, proceed with step 3.
3. Let the motor run at idle and use a stethoscope or Steel screwdriver to determine which bank is
noisy. Once you have determined the location, turn the key off. (Figure 1)
4. Remove the cylinder head cover on the noisy bank.
5. Inspect each rocker arm for clearance at the valve (when the rocker is on the base circle of the
cam and the valve is closed). The noisy rocker arms are the ones with clearance. (Figure 2)
NOTE:
Each cylinder head has one oil pressure relief valve that controls oil pressure to its rocker arms. If
all rocker arms on one cylinder head have clearance and/or the rocker arm pivot shaft is worn, then
the cylinder head oil pressure relief valve may be stuck open. In this case, refer to the appropriate
Workshop Manual for additional troubleshooting procedures.
6. Remove the ticking rocker arm assembly, and inspect the wear pattern of the hydraulic lash
adjuster surface that contacts the valve stem (the intake rocker arm is located under the camshafts,
which require timing belt removal).
7. Carefully remove the Hydraulic Lash Adjuster(s) from the Rocker Arms using your fingers.
(Figure 4)
IMPORTANT:
Do not damage the O-Ring on the outside of the Hydraulic Lash Adjuster, or you will have to
replace the entire rocker arm (the Hydraulic Lash Adjuster cannot be ordered separately). When
replacing an exhaust rocker arm, replace its intermediate rocker arm too.
8. Insert a paper clip into the hole at the top of the Hydraulic Lash Adjuster and depress the spring
loaded check ball, while completely pushing in the piston at the opposite end. Some traces of oil
may come out of the check ball hole. (Figure 5)
9. Carefully remove and retain the Hydraulic Lash Adjuster O-Ring. Spray the Hydraulic Lash
Adjuster piston with carburetor cleaner to remove any varnish (while holding the piston in). (Figure
6)
10. Submerge the Hydraulic Lash Adjuster in new cleaning solvent; (while depressing the check
ball) pump the piston repeatedly to allow the cleaning solvent to penetrate through the Hydraulic
Lash Adjuster. (Figure 7)
11. Submerge the Hydraulic Lash Adjuster in clean 0W-30 Mobil 1 synthetic engine oil, (while
depressing the check ball) pump the piston repeatedly to allow 0W-30 Mobil 1 synthetic engine oil
to penetrate through the Hydraulic Lash Adjuster. Then allow the piston to extend fully, to fill the
Hydraulic Lash Adjuster with oil.
12. Reinstall the Hydraulic Lash Adjuster O-Ring.
13. Lube the Rocker Arm bore that houses the Hydraulic Lash Adjuster with 0W-30 Mobil 1
synthetic engine oil, then push the Hydraulic Lash Adjuster back into place.
14. Inspect for leaks at the check ball and piston by attempting to compress the Hydraulic Lash
Adjuster without depressing the check ball (The Hydraulic Lash Adjuster should not leak or
compress).
NOTE:
Oil filled Hydraulic Lash Adjuster will hold its valve off the seat for several crank revolutions. This
may cause the engine to run rough for a short period after starting. To prevent this, select one
cylinder and bleed some oil off the Hydraulic Lash Adjuster (depress the Check Ball and compress
the piston 1/4 of the way down). This will allow the valve to close. Do not remove all of the oil or the
valves spring and cam will collapse the Hydraulic Lash Adjuster permanently.
15. Reassemble the engine using new cylinder head cover gasket (see Parts Information) and
apply some gasket seal at the corners where the cam tower gasket and cylinder meet. Torque the
Cylinder head cover bolts to 8 Nm (69 lb. in) using hand tools only.
16. Start the engine and listen for noise.
17. Remind the customer, "More frequent oil changes can prevent varnish accumulation." Also
recommend to use minimum oil rating of: API Service SG, but SJ is preferred.
Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 > Engine
Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Valve Train - Ticking Noise > Page 540
Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 544
Valve Clearance: By Symptom
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
GROUP: ENGINE
NOTE:

AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION
Service Procedure

NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Valve Clearance: Specifications
Stem Diameter:
Intake ...................................................................................................................................................
...................................... 0.2346-0.2323 inches Exhaust .....................................................................
................................................................................................................. 0.2343-0.2323 inches
Face Angle, Degrees ...........................................................................................................................

............................................................................... 45 Valve Clearance:
Intake ...................................................................................................................................................
.................................................................. [01] Exhaust ......................................................................
............................................................................................................................................ [01]
[01] -- Hydraulic lifters, no adjustment is necessary.

Valve Clearance: Adjustments
These engines use hydraulic valve lifters. No valve adjustment is possible.

Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Testing and Inspection
Timing Belt: Testing and Inspection
TIMING BELT INSPECTION
Visual check
1. The belt must be replaced if cracks or lacerations are found in the side and rear faces.
2. replacement is necessary when abnormal wear is found in the side face.
3. Replacement is necessary when belt fabric is found to be cracked or disintegrated.
4. Replacement is also necessary when cogs are found to have abnormal wear.
5. Take measurements at 3 - 5 points around the circumference of the belt The belt must be
replaced even if a single measurement is beyond the limit.
Limit of rubber hardness - 90 (HS)

Isuzu Workshop Manuals > Maintenance > Timing Belt > Component Information > Testing and Inspection > Page 559
Timing Belt: Service and Repair
REMOVAL STEPS
Preparation: Battery ground cable
1. Radiator upper fan shroud
- Remove from radiator.
2. Cooling fan assembly
- Remove four nuts, then the cooling fan assembly.
3. Power steering pump drive belt
4. Air Conditioning compressor drive belt
5. Generator drive belt
6. Power stering pump drive belt
7. Fan pulley assembly
8. Crankshaft pulley assembly

- Using special tool J-8614-O1, hold crankshaft pulley.
- Remove center bolt, then the pulley.
10. Oil cooler hose
- Remove two cooler hose bracket fixing bolts on the timing cover.
11. Timing belt cover
12. Pusher
CAUTION: -
The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.
INSTALLATION STEPS
To install, follow the removal steps in the reverse order.
13. Timing belt
CAUTIONS: -
Do not bend or twist the belt, otherwise its core could be damaged. The belt should not be bent at a
radius less than 3Omm.
- Do not allow oil or other chemical substances to come in contact with the belt. They will shorten
the belt life.
- Do not attempt to pry or stretch the belt with a screwdriver or any other tool during installation.
- Store timing belt in a cool and dark place. Never expose the belt to direct sunlight or heat.
1) Align groove of crankshaft timing pulley with mark on oil pump.

2) Align the marks on the camshaft timing pulleys with the corresponding dots on the front plate.
NOTE: -
When timing marks are aligned, no pistons will be on T.D.C.
3) Install timing belt. Align the dotted alignment mark on the timing belt with the mark on the
crankshaft gear.
NOTE: -
For correct belt installation, the letters the belt must be able to be read as viewed from the front of
the vehicle. It is recommended for easy installation that the belt be secured with double clips after it
is installed to each pulley.
4) Align the alignment mark (white line) on the timing belt with the alignment mark on the RH bank
camshaft timing pulley (on the left side as
viewed from the front of the vehicle Secure the belt with a double clip.
5) Turn the crankshaft counterclockwise to remove the belt slack between the crankshaft timing
pulley and the RH bank camshaft timing pulley.
6) Install the belt on the water pump pulley.
7) Install the belt on the idler pulley.
8) Align the alignment mark (white line) on the timing belt with the alignment mark on the LH bank
camshaft timing pulley. If the belt is difficult
to install turn the camshaft pulley slightly counterclockwise.
9) Install crankshaft pulley temporarily and tighten center bolt by hand (do not use a wrench). Turn
the crankshaft pulley clockwise to give some
slack between the crankshaft timing pulley and the RH bank camshaft timing pulley.
10) Install the pusher while pushing the tension pulley to the belt.
11) Pull out the pin from the pusher.
NOTE: -
When reusing the pusher, press the pusher to retract the rod and insert a pin (1.4 mm piano wire).
12) Remove double clips from pulleys. Turn the crankshaft pulley clockwise by two turns. Measure
the rod protrusion to ensure it is within the
standard.
Standard 4-6 mm (0.16-0.24 in)

13) If out of standard, remove pusher, loosen adjusting bolt, and readjust. (Repeat from step 11).
Tighten adjusting bolt to the specified torque.
12. Pusher
- Tighten bolt to the specified torque.
- Remove crankshaft pulley that was installed in step 9.
- Tighten bolts to the specified torque.
10. Oil cooler hose
- Tighten oil cooler hose bracket bolts to the specified torque.
- Using special tool J-8614-01, hold the crankshaft pulley.
- Tighten center bolt to the specified torque.
8. Crankshaft pulley; P/S belt

- Tighten fixing bolt to the specified torque.
Torque 9 N-m (78 lb-in)
6. Power steering tension pulley
- Engage and adjust with adjuster.
4. Air Conditioning drive belt
- Tighten nuts to the specified torque.

Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 9301005 > May > 93 > Alternator Belt - Squeaking Noise
Drive Belt: All Technical Service Bulletins Alternator Belt - Squeaking Noise
ISSUE DATE May 1993
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) BELT NOISE (COLD START)
AFFECTED VEHICLES
1992-93 Trooper (UX) and Rodeo (UC) models equipped with 3.2L V6 engine.
SERVICE INFORMATION
At cold engine start-up, some affected vehicles may experience a squeaking noise coming from the
alternator belt. To eliminate the noise, adjust the alternator belt tension to 110 +/- 10 lbs.
Alternator belt tension specifications are incorrectly printed in the following Workshop Manuals:
Correct alternator belt tension specifications (cold engine) for referenced Workshop Manuals for
3.2L V6 engine are:
Initial Tension 180 +/- 10 lbs.
Readjustment Tension 110 +/- 10 lbs.

Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 9301005 > May > 93 > Alternator Belt - Squeaking Noise
Drive Belt: Customer Interest Alternator Belt - Squeaking Noise
ISSUE DATE May 1993
GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
3.2L V6 engine are:

Isuzu Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 578
Drive Belt: Specifications
CAUTION: ^
It is strongly advised to use a tension gauge to check the tension of this belt. Checking tension by
"feel" of belt is not accurate. Tension should be checked using a tension gauge after installation
and break-in (about 1,000 km or 620 miles).
^ Tension readjustment of auto tension belt should be made only once when V-type HM' tension
has dropped to 40 lb or less and poly V type's to 50 lb or less after the vehicle's total running
mileage of 621 miles.
^ As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge.
Depress belt with 98N (22 lb) and make sure that slackness is in the range of 8 - 12mm (0.315
0.472 in).
Belt tension range to be targeted for cold setting. using a Borrough drive belt tension gauge.
DRIVE BELT ADJUSTMENT
TENSION ADJUSTMENT Generator & fan pulley drive belt Loosen generator fixing bolt and
adjuster lock bolt. Adjust bolt by turning adjust bolt. After installation, tighten lock bolt to the
specified tightening torque.
Fixing bolt
Lock bolt
A/C compressor drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After installation
tighten lock bolt to the specified tightening torque.
Power steering oil pump drive belt Loosen lock bolt and adjust bolt by turning adjust bolt. After
installation tighten lock bolt to the specified tightening torque.
Drive Belt: Testing and Inspection
INSPECTION
Check drive belts for wear or damage, and replace with new ones as necessary. Check belts for
tension, and adjust as necessary.
CAUTION: It is strongly advised to use a tension gauge to check the tension of this belt. Checking
tension by "feel" of belt is not accurate. Tension should be checked using a tension gauge after
installation and break-in (about 1,000 km or 620 miles). Tension readjustment of auto tension belt
should be made only once when V-type HM' tension has dropped to 40 lb or less and poly V type's
to 50 lb or less after the vehicle's total running mileage of 621 miles. ^
As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge.
Depress belt with 98N (22 lb) and make sure that slackness is in the range of 0.315 0.472 in.
Belt tension range to be targeted for cold setting. Using a Borrought drive belt tension gauge.
Drive Belt: Adjustments
Fixing bolt
Lock bolt
Isuzu Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Filter <--> [Air Filter Element] >
Component Information > Description and Operation
Air Filter
PURPOSE
OPERATION
chamber.
CONSTRUCTION

Component Information > Description and Operation > Page 586
REMOVAL

CLEANING
INSTALLATION
3. Air cleaner hose

Isuzu Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions
following items:
lubricated.)
Isuzu Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 592
Isuzu Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions
Hoses: Service Precautions
SERVICE PRECAUTIONS
To prevent vehicle damage, always observe the following precautions: -
After servicing a hose, check for leaks before and after test driving the vehicle.
- Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice
versa.
Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use
heater hose in place of PCV hose.
- When replacing hoses which are attached to the engine on one end and the frame or body on the
other end, always leave sufficient length to compensate for engine movement (from torque).
Isuzu Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Fluid Type DOT 3 or 4

Isuzu Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications
Type .....................................................................................................................................................
.................................... DOT-3 hydraulic brake fluid
Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Acceptable for Use
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Acceptable for Use
ISSUE DATE
JANUARY 1996
GROUP MISCELLANEOUS
PROPYLENE GLYCOL - BASED ENGINE COOLANT (Supersedes SB94-14-005)
AFFECTED VEHICLES
All Isuzu passenger, sport utility, and light truck models.
SERVICE INFORMATION
Isuzu has determined that propylene glycol-based engine coolants, such as Safe Brands' Sierra
engine coolant, will perform adequately under most vehicle operating conditions. As a result,
propylene glycol-based engine coolants may be used in Isuzu vehicles.
A few important points to remember regarding propylene glycol-based engine coolants:
^ Freeze/boil point levels for propylene glycol are different than for ethylene glycol.
^ To accurately determine the freeze/boil protection level, it is imperative that the coolants not be
mixed.
^ Prior to adding propylene glycol engine coolant to the cooling system, all ethylene glycol coolant
must be removed.
^ When changing the coolant to propylene glycol, be certain to thoroughly flush the heater core and
block as well as the radiator.
Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Acceptable for Use > Page 607
Coolant: Technical Service Bulletins Coolant - Propylene Glycol Not Approved by Isuzu
ISSUE DATE DECEMBER 1994
GROUP MISCELLANEOUS
PROPYLENE GLYCOL-BASED ENGINE COOLANT WARNING
AFFECTED VEHICLES
All Isuzu passenger and light duty models.
SERVICE INFORMATION
Some new propylene glycol-based engine coolants, such as Safe Brands' Sierra engine coolant,
have recently been marketed in the automotive service industry as "environmentally safe"
alternatives to conventional ethylene glycol-based engine coolants.
Propylene glycol-based engine coolants are not approved by Isuzu for use in Isuzu vehicles.
Propylene glycol-based engine coolants do not meet Isuzu engine coolant specifications. Use of
propylene glycol-based engine coolants in Isuzu vehicles can cause the following:
^ Reduced heater and defroster performance.
^ Decreased boil protection and freeze protection.
^ Decreased cylinder head heat transfer.
^ Corrosion damage to cooling system metals (if mixed with ethylene glycol-based engine coolant).
Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity, Quarts:
Manual Transmission ..........................................................................................................................

.................................................................... 9.7 Automatic Transmission ...........................................
............................................................................................................................................... 9.3
Isuzu Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Coolant: Fluid Type Specifications
EC - Ethylene Glycol Coolant

Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Dexron-IIE Fluid - Recommended Usage
Fluid - A/T: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage
BULLETIN NUMBER: SB93-14-003
ISSUE DATE April 8, 1993
GROUP MISCELLANEOUS
USE OF DEXRON(R)-IIE FLUID
AFFECTED VEHICLES
All ISUZU models using DEXRON(R)-II fluid in the transmission or powersteering system.
SERVICE INFORMATION
Effective 12/31/92, DEXRON(R)-II was replaced by DEXRON(R)-IIE fluid, which is an upgraded

version of the same product.
DEXRON(R)-IIE meets all of the DEXRON(R)-II requirements and should be used for all previous
DEXRON(R)-II applications.
Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Capacity ...............................................................................................................................................
.......................................... 8.6 Liter (9.1 US quarts)
Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Fluid - A/T: Fluid Type Specifications
Type .....................................................................................................................................................
.............. DEXRON-II Automatic transmission fluid
Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Dexron-IIE Fluid - Recommended Usage
Fluid - M/T: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage
GROUP MISCELLANEOUS
AFFECTED VEHICLES
SERVICE INFORMATION

Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications
Fluid - M/T: Capacity Specifications
BW Type Manual Transmission
OIL VISCOSITY CHART FOR MANUAL TRANSMISSION AND TRANSFER CASE
Capacity ...............................................................................................................................................
.................................................. 2.25 Liter (2.4 qts.)
MUA Type Manual Transmission
Capacity ...............................................................................................................................................
.................................................. 2.95 Liter (3.1 qts.)
Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid
Ambient Temperature >90°F ...............................................................................................................

............................................................ SAE 40 Other Areas ...............................................................
............................................................................................................................... SAE 5w/30*
*Preferred
Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
1990-94 W/Saginaw rear axle

.......................................................................................................................... 80W-90 GL-5(Gear
Oil, API Service GL-5) All Others ........................................................................................................
.............................................................................................................. GL-5
Above 50°F (10°C) ..............................................................................................................................

............................................................................ 140 0° to 90°F (-18° to 32°C) .................................
..............................................................................................................................................................
.... 90 Below 50°F (10°C) .....................................................................................................................
.............................................................................. 80W-90
CAPACITY, Refill: Front ......................................................................................................................

................................................................................. 1.5 liters 3.2 pints Rear:
2.3L ......................................................................................................................................................
............................................ 1.5 liters 3.2 pints 2.6L, 2.8L, 3.1L, 3.2L ................................................
...................................................................................................................... 1.8 liters 3.8 pints All
with Saginaw axle ................................................................................................................................
....................................... 1.9 liters 4.0 pints
Saginaw axle has removable rear cover without fill plug.

Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Fluid - Differential: Fluid Type Specifications
OIL VISCOSITY CHART FOR FRONT AXLE AND REAR AXLE
TYPE ...................................................................................................................................................
.................................................. GL-5 gear lubricant
Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
W/Manual Transmission
.....................................................................................................................................................
SG(Motor Oil, API Service SG)
Above 90°F (32°C) ..............................................................................................................................

........................................................................ 40 All temperatures ....................................................
................................................................................................................................................ 5W-30
W/Automatic Transmission:
4-cyl. ....................................................................................................................................................
....................................................................... AF V6 ...........................................................................
.................................................................................................................................................... SG
Above 90°F (32°C) ..............................................................................................................................

.............................................................................. 40 All temperatures ..............................................
............................................................................................................................................................
5W-30
CAPACITY, Refill: Man. trans ..............................................................................................................

................................................................................. 1.5 liters 3.2 pints Auto. trans.:
4-cyl. ....................................................................................................................................................
............................................. 0.8 liters 1.6 pints V6 .............................................................................
........................................................................................................................ 1.5 liters 3.2 pints
Isuzu Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 634
Fluid - Transfer Case: Fluid Type Specifications

Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting
Engine Oil: All Technical Service Bulletins Engine - Oil Usage Testing and Reporting
2007 Service Bulletins TSB SB07-01-S001
ISSUE DATE: JANUARY 2007 Engine Oil Usage Testing and Reporting (This Bulletin Supersedes
SB04-01-S004)
Affected Vehicles
All Light Duty Isuzu Vehicles
Service Information
This bulletin has been revised to include new mileage information for Ascender, i-280, i-290, i-350,
and i-370 vehicles and to update Model Years.
Before performing any warranty repairs, based on a customer's complaint of excessive engine oil
consumption, the attached Engine Oil Usage Test/Report must be completed in full.
Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page
643
644
645
646
The updated Engine Oil Usage Test / Report is divided into two parts, PROCEDURE # 1 and
PROCEDURE # 2.
Procedure # 1, the inspection and testing portion of the Engine Oil Usage Test / Report, are eligible
for warranty submission. Procedure # 1 warranty claim may only be submitted ONE time per
vehicle. Review Procedure # 1 Results and perform the appropriate action.
Complete all steps in Procedure #1 before continuing on to Procedure # 2 (if required).
Procedure # 2, the validation portion, is NOT reimbursable under warranty. Complete all steps in
Procedure # 2. Review Procedure # 2
Results and perform the appropriate action.
The Technician, Service Manager and Customer are to acknowledge the findings by signing and
dating the bottom of the Engine Oil
Usage Test / Report. Attach a copy of the completed report to the back of the Repair Order (R/O)
hard copy and provide a copy to the customer.
NOTE:
1. Normal authorization procedures must be followed for such repairs.

647
2. Information released on paper and electronic format prior to bulletin release cannot be updated.
For the most current and up to date information refer to website.
All engines require oil to lubricate and protect the load bearing and internal moving parts from wear
including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film
of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the
combustion process. As a result, varying rates of oil consumption are accepted as normal in all
engines.
Oil Consumption
The accepted rate of oil consumption for engines used in Ascender, i-280, i-290, i-350, and i-370
vehicles is 1 quart (0.946 liter) in 2,000 miles (3200 km).
The accepted rate of oil consumption for engines used in Trooper (UX), Axiom (UP), VehiCROSS
(VX), Rodeo (UE), and Rodeo Sport/Amigo (UA) vehicles is 1 quart (0.473 liter) in 1,000 mi (1600
km).
IMPORTANT:
Always refer to the Isuzu Service Policies and Procedures Manual for specific details on warranty
coverage and policies.
This rate only applies to personal use vehicles, under warranty, that are driven in a non-aggressive
manner and maintained in accordance with the appropriate maintenance schedule, with less than
36,000 miles (58,000 km), driven at legal speeds in an unloaded (for trucks) condition.
IMPORTANT:
This rate does not apply to vehicles that are driven in an aggressive manner, at high RPM, high
speeds, or in a loaded condition (for trucks). Oil consumption for vehicles driven under these
conditions will be more.
Many factors can affect a customer's concern with oil consumption. Driving habits and vehicle
maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether
the vehicle in question has abnormal engine oil consumption.
Gasket and External Leaks
Inspect the oil pan and engine covers for leakage due to overtightened, damaged, or out of place
gaskets. Inspect oil lines and fittings for signs of leakage.
Improper Reading of the Oil Level Indicator (Dipstick)
Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the
dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the
shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the
engine/vehicle that is being checked.
IMPORTANT:
Refer to the Owner Manual for checking and adding engine oil.
Not Waiting Long Enough After Running Engine to Check Oil Level
Some engines require more time than others for the oil to drain back into the crankcase. To assure
a sufficient amount of oil has drained back to the crankcase, and an accurate reading can be
obtained, the vehicle should be allowed to sit for at least 15 minutes, after the engine has been
shut off, before taking an oil level reading. In order to ensure accurate results, the temperature of
the oil should be close to the same temperature as the last time the oil level was checked.
Improper Oil Fill After an Oil Change

Following an oil change, verify that the proper amount and type of oil was put in the engine and that
the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's
Manual or Service Manual for information on recommended oil quantity, viscosity, and quality.
Aggressive Driving, High Speed or High RPM Driving
Aggressive driving and/or continuous driving at high speeds/high RPM will increase oil
consumption. Because this may not always be an everyday occurrence, it is hard to determine
exactly how much the oil economy will be affected.
Towing or Heavy Usage
Towing a trailer will increase oil consumption and may cause oil consumption to fall below the
normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use
application. Large frontal area trailers will further increase the work required from the engine,
especially at highway speeds, and thus increases the rate of oil consumption.
648
Crankcase Ventilation System
Verify that the positive crankcase ventilation (PCV) system is operating properly. Blockages,
restrictions, or damage to the PCV system can result in increased oil use.
Oil Dilution (Fuel and Water)
On vehicles that are usually driven short distances, less than 5 miles (8 km), especially in colder
weather, unburned fuel and condensation generated from cold engine operation may not get hot
enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is
over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating
temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the
customer the impression of excessive oil consumption.
Engine Temperature
If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more
than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort,
piston rings may stick, and excessive wear may result. Verify that all cooling system components
are in proper working order.
Engine Wear
Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn,
damaged or improperly installed valve guides, seals and piston rings will all cause an increase in
oil consumption.
Disclaimer
Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 653
Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 662
Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting
SB04-01-S004)
Affected Vehicles
Service Information
Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine - Oil Usage Testing and Reporting > Page 671
PROCEDURE # 2.
NOTE:

engines.
Oil Consumption
km).
IMPORTANT:
IMPORTANT:
IMPORTANT:
Engine Temperature
Engine Wear
oil consumption.
Disclaimer
Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil Refill, quarts including filter ................................................................................................

........................................................................... 5.7
Isuzu Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Engine Oil: Fluid Type Specifications
Oil Viscosity
Engine Oil Type ......................................... SG, SF, SE/CC or SE Engine Oil

Isuzu Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Dexron-IIE Fluid - Recommended Usage
Power Steering Fluid: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage
GROUP MISCELLANEOUS
AFFECTED VEHICLES
SERVICE INFORMATION

Isuzu Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Power Steering Fluid: Specifications
GENERAL SPECIFICATIONS
Fluid Type ............................................................................................................................................

................................................... Dexron-II E ATF
Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - SAE J2788 Refrigerant Recovery Standard
Refrigerant: Technical Service Bulletins A/C - SAE J2788 Refrigerant Recovery Standard
Information: IB07-12-S004
Issue Date: AUGUST 2007
New SAE J2788 Refrigerant Recovery Standard
Affected Vehicles All Isuzu Light Duty Vehicles
Service Information
A new SAE standard approved for R134a Refrigerant Recovery Recharging Equipment (SAE
J2788) replaces SAE J2210 as the standard covering all mobile refrigerant recovery recharge
equipment. SAE J2788 contains several mandates that enhance vehicle A/C service for two key
reasons. The standard reduces the amount of refrigerant that can be lost to the atmosphere due to
growing concerns over global warming and greenhouse gas emissions. The standard also more
tightly controls the equipment accuracy for recharging due to OEM vehicle system refrigerant
capacities becoming smaller, which requires a more accurate charge for peak operating
performance. SAE J2788 will supersede J2210 in December 2007. At this time manufacturers will
no longer be able to produce J2210 equipment.
IMPORTANT:
This new standard does not affect equipment already produced before December 2007. You DO
NOT have to replace the equipment that you are currently using.
The Environmental Protection Agency (EPA) is currently in the process of rewriting the Federal
Registry, which will likely prohibit sale of SAE J2210 equipment at the end of March 2008.
^ The EPA does not currently have a plan to ban the use of J2210 equipment.
^ Current J2210 equipment can continue to be used by service locations for the useful life of the
equipment.
^ Purchase of new compliant equipment is not a requirement of SAE J2788 or the EPA.
New machinery built after December 2007 will meet or exceed the new specifications.
The SPX Robinair model 34788 was the first product certified to J2788 and has been in full
production and in service since December 2006. It meets all requirements outlined above and
includes numerous user friendly features beyond the SAE standard.
Please contact Isuzu Dealer Equipment Program Customer Service for additional product
information.
Disclaimer
Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - SAE J2788 Refrigerant Recovery Standard > Page 689
Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Precautions
2006 Service Bulletins
Information IB06-12-S001
Contaminated R134A Refrigerant Found On Market For Automotive Air-Conditioning Systems
ISSUE DATE: AUGUST 2006
Affected Vehicles
All Isuzu Vehicles using R134a Refrigerant
Service Information
Commercially Available Contaminated R134a Refrigerant
Impurities have been found in new commercially available containers of R134a. High levels of
contaminates may cause decreased performance, and be detrimental to some air-conditioning
components. Accompanying these contaminates has been high levels of moisture.
NOTE:
Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced
performance.
Industry Reaction: New Industry Purity Standards
Due to the potential availability of these lower quality refrigerants, the Society of Automotive
Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of
instituting reliable standards that will be carried on the labels of future R134a refrigerant containers.
This identifying symbol will be your assurance of a product that conforms to the minimum standard
for OEM Automotive Air-Conditioning use.
How Can You Protect Yourself Today?
It is recommended to use Isuzu sourced refrigerants for all A/C repair work. These refrigerants
meet Isuzu Motors America, Inc.'s own internal standards for quality and purity.
Parts Information
Disclaimer
Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Refrigerant Type R-12
System Capacity 1.65 lb (US)

Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Refrigerant: Fluid Type Specifications
Refrigerant Type ..................................................................................................................................

.......................................................................... R-12
Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 693
Refrigerant: Service Precautions
Service Procedures
The Ozone Layer
A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by
absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun.
Ozone Depletion
Scientific research performed over the past 15 years links the release of chlorofluorocarbons
(CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFC's
are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere
where they react with and destroy ozone molecules.
Harmful Effects
Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher
incidents of cancer as well as global warming. When viewed from a global perspective, ozone
depletion holds an enormous potential for damage.
Upper Level vs. Ground Level Ozone
Confusion often arises when we hear about the necessity of the ozone layer and ground level
ozone. The ozone layer existing high above the earth is beneficial but the same compound, when
located at ground level, is harmful to humans, animals, crops and vegetation.
Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with
nitrogen oxides (NOx) in the presence of sunlight and heat.
Montreal Protocol
In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24
countries and the European community met in Montreal, Canada, in 1987 to establish standards for
the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this
agreement leading to an end of production of R12 in December, 1995, in all developed countries.
As established by the Montreal Protocol, R12 production in developed countries has ceased.
Clean Air Act
The United States Congress, acting in response to the Montreal Protocol, banned production of
(CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the
production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning
systems.
Alternative Refrigerants
The introduction of alternative refrigerants, primarily the hydrofluorocarbon (HFC) 134a, aims at
preventing further ozone layer depletion. Because 134a is chlorine free, it is deemed ozone safe.
Technician Certification
Organizations providing technician refrigerant recovery and recycling certification include:
National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2
Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/
International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX
76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451
Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041
Phone: 215-679-2220 Fax: 215-541-4635 http://www.macsw.org/
Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Oil Type/Viscosity DKV-14D Compressor D-220WX
or equivalent.
DKS-17CH Compressor FREOL DS-83P
or equivalent.
Total System Capacity 5.0 oz (US)

Isuzu Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Refrigerant Oil: Fluid Type Specifications
Oil Type/Viscosity R-4 Compressor 525
DKS-13 Compressor FREOL DS-83P
or equivalent.
Isuzu Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair
Brake Bleeding: Service and Repair
Bleeding operation calls for co-operative action of two persons. Perform bleeding operation with
``Engine Running,'' to prevent damage to pushrod seal. Ensure exhaust system is suitably
ventilated.
1. Set the parking brake firmly. 2. If diaphragm in the reservoir cap is stretched, reform to original
position or replace as necessary. Fill the brake fluid reservoir with recommended
brake fluid, then install cap.
3. Connect a vinyl hose to the bleeder screw and the other end of the pipe in a transparent
container. 4. Pump the brake pedal several times and hold it depressed. Loosen the bleeder screw
to release brake fluid together with air bubbles. Tighten the
bleeder screw before pressure is released completely.
5. Repeat Step 4 until the air bubbles are no longer visible, bleed the system starting with the rear
side farthest from the brake fluid reservoir. Check
brake fluid reservoir often, adding fluid as necessary.

Isuzu Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions >
Air Bag Assembly Handling/Shipping/Scrapping
Air Bag(s) Arming and Disarming: Service Precautions Air Bag Assembly
Handling/Shipping/Scrapping
Undeployed Air Bag
NOTE: Refer to the latest service bulletins for proper SRS inflator module shipping procedures.
CAUTION: When you are performing service on or near the SRS components or the SRS wiring,
you must disable the SRS. Failure to follow the correct procedure could cause air bag deployment,
personal injury, or unnecessary SRS repairs.
1. Air bag assembly should not be subjected to temperatures above 93°C (200°F).
2. Air bag assembly, and Sensing and Diagnostic Module (SDM) should not be used if they have
been dropped from a height of 100 cm (3.28 feet).
3. When a SDM is replaced, it must be oriented with the arrow on the sensor pointing toward the
front of the vehicle. It is very important for the
SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important
that the SDM mounting surface is free of any dirt or other foreign material.
4. Do not apply power to the SRS unless all components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code.
5. The "SRS Diagnostic System Check" must be the starting point of any SRS diagnostics. The
"SRS Diagnostic System Check" will verify proper
"AIR BAG" warning lamp operation and will lead you to the correct chart to diagnose any SRS
malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacement.
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a live (undeployed) air bag assembly. The
rapid gas generation produced during deployment of the air bag could cause the air bag assembly,
or an object in front of the air bag assembly, to be thrown through the air in the unlikely event of an
accidental deployment.
Air Bag Assembly Handling/Shipping/Scrapping > Page 706
WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG OPENING
IS POINTED AWAY FROM YOU. IN CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL
THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. NEVER CARRY THE AIR BAG
ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF THE MODULE.
Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies
Service personnel should refer to the latest Service Bulletins for proper Supplemental Restraint
System (SRS) air bag assembly shipping procedures.
Air Bag Assembly Scrapping Procedure
During the course of a vehicle's useful life, certain situations may arise which will necessitate the
disposal of a live (undeployed) air bag assembly. This information covers proper procedures for
disposing of a live air bag assembly. Before a live air bag assembly can be disposed of, it must be
deployed. Alive air bag assembly must not be disposed of through normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL

PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL
INJURY. AN UNDEPLOYED AIR BAG ASSEMBLY MUST NOT BE DISPOSED OF THROUGH
NORMAL REFUSE CHANNELS.THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED
CONTAINER IS DAMAGED DURING DISPOSAL.DISPOSAL IN ANY MANNER INCONSISTENT
WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE, AND / OR LOCAL
LAW.
In situations which require deployment of a live air bag assembly module, deployment may be
accomplished inside or outside the vehicle. The method employed depends upon the final
disposition of the particular vehicle, as noted in "Deployment Outside Vehicle" and "Deployment
Inside Vehicle" in this section.
Deployed Air Bag
Deployed Air Bag Assembly
WARNING: You should wear gloves and glasses. After the air bag assembly has been deployed,
the surface of the air bag may contain solid particulate. This solid particulate consists primarily of
by-products of the chemical reaction, Potassium Chloride and copper metal dust. Compounds of
Potassium Borate, Strontium Chloride, Copper Chloride, and Ammonium Chloride may be found in
amounts of about 1% (each) of the total particulate."
Driver Airbag Assembly
After the air bag assembly has been deployed, the surface of the air bag may contain solid
particulate. This solid particulate consists primarily of by products of the chemical reaction,
Potassium Chloride and copper metal dust. Compounds of Potassium Borate, Strontium Chloride,
Copper Chloride, and Ammonium Chloride may be found in amounts of about 1% (each) of the
total particulate.
Passenger air bag assembly
Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible
irritation and heat when handling the deployed air bag assembly.
After the air bag assembly has been deployed, the surface of the air bag may contain a powdery
residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and
by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a
by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric
moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore,
it is unlikely that sodium hydroxide will be present after deployment.
Air Bag(s) Arming and Disarming: Service Precautions Electrical Test Equipment
Air Bag(s) Arming and Disarming: Service Precautions Fasteners
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.
CAUTION: When fasteners are removed, always reinstall them at the same location from which
they were removed. if a fastener needs to be replaced, use the correct part number fastener for
that application. if the correct part number fastener is not available, a fastener of equal size and
strength (or stronger) may be used. fasteners that are not reused, and those requiring thread
locking compound will be called out. the correct torque value must be used when installing
fasteners that require it. if the above conditions are not followed, parts or system damage could
result.
Air Bag(s) Arming and Disarming: Service Precautions Wiring
diagnose.
Page 711
Air Bag(s) Arming and Disarming: Service and Repair
PRECAUTIONS
1. To avoid accidental deployment and possible personal injury, always disarm the system prior to
performing service procedure. Wait at least ten
minutes after disconnecting the cable prior to performing any service. The SIR System is designed
to retain enough voltage to deploy the air bag for a short time even after the battery ground cable
has been disconnected. Performing service before a minimum of ten minutes has elapsed may
cause air bag deployment and possible injury.
2. To avoid deployment when troubleshooting the SIR system, do not use electrical test equipment,
such as battery powered or A/C powered
voltmeter, ohmmeter or any type of electrical equipment other than specified. Do not use a
non-powered probe type tester.
3. The passenger compartment sensors must always be installed with arrow mark facing the front
of the vehicle for proper operation. 4. Check sensors for cracks, deformities or rust before
installation and replace as required. 5. When handling or storing an air bag module, always position
with the pad side facing upward. 6. Keep air bag assembly free of oil, grease, detergents and
water. 7. Do not expose air bag assembly to temperatures that exceed 212° F. 8. Do not use SIR
system components from another vehicle. Always install new replacement components on vehicle.
9. Inspect all components prior to installation. Do not install any components that appear to have
been improperly handled or stored or that show any
signs of damage.
10. When performing service procedure, do not expose sensors/wiring or other SIR system
components to heat guns, welding or spray guns.
Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations
Dash Fuse Box

Isuzu Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
> Diagram Information and Instructions > Page 720

Fuse Block: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Fuse Block: Electrical Diagrams
Dash Fuse Box: Fuse 3


Dash Fuse Box: Fuses 5, 6, And 7


Dash Fuse Box: Fuses 8 And 10

Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > Oxygen Sensor ( O2 ) Lamp <--> [Maintenance
Required Lamp/Indicator] > Component Information > Service and Repair
Oxygen Sensor ( O2 ) Lamp: Service and Repair
Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Malfunction Indicator Lamp: Locations
In the instrument cluster.

Information > Locations > Page 753
Malfunction Indicator Lamp: Description and Operation
PURPOSE
Illuminates when a influencing occurs that will affect emission control performance. Flashes trouble
codes (DTC) during testing operations.
LOCATION
OPERATION
When the system detects a fault in a monitored component and/or circuit, the light will come on and
stay on (while the engine is running), alerting the driver to seek service. With intermittent problems,
the light may come on and then go out, but a trouble code will be stored in ECM memory if correct
parameters are met. The technician can then extract trouble codes from the ECM that will aid in the
diagnosis and repair.
Another function of the "Check Engine" light is Field Service Mode. When the diagnostic terminal is
grounded with the engine running, the system will enter this mode and indicate whether it is in
"Open Loop" or "Closed Loop." If in "Open Loop," the "Check Engine" light flashes two and one-half
times per second. In "Closed Loop," the light flashes once per second.
In "Closed Loop", the light will stay "OFF" most of the time if the system is running too lean. It will
stay "ON" most of the time if the system is too rich.
While in Field Service Mode, new trouble codes cannot be stored in the ECM memory and the
"Closed Loop" timer is bypassed.
Malfunction Indicator Lamp: Testing and Inspection

Isuzu Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp - A/T > Component
Information > Description and Operation
Malfunction Indicator Lamp - A/T: Description and Operation
CIRCUIT DESCRIPTION
The "CHECK TRANS" indicator is lit at the beginning of every ignition cycle for 2 to 4 seconds
while the TCM performs a self-test of the circuit and components. When the TCM detects an
electrical failure in the system (ignition switch on), TCM will turn the "CHECK TRANS" indicator on
and store a trouble code in its memory. Note that most electrical failures will cause the TCM to
enter the backup mode.
The TCM also uses the "CHECK TRANS" indicator to display trouble codes by flashing the
indicator. When the Tech-1 is connected to the TCM diagnostic system, the "CHECK TRANS"
indicator flashes continuously.
Information > Description and Operation > Page 758
Malfunction Indicator Lamp - A/T: Testing and Inspection
CIRCUIT DESCRIPTION
NOTE: This test assumes the following: - Either "CHECK TRANS" indicator is on at all times
(ignition is on) and no trouble codes are stored, or - "CHECK TRANS" indicator does not light and
the Tech-1 is able to receive data from the TCM.
NOTE: For all 1990-93 models: - In addition to its diagnosis-related function, the "CHECK TRANS"
indicator will be constantly on (not flashing) if the transmission oil
temperature is above 293°F (145°C).
- The "CHECK TRANS" indicator will go oft again when the transmission oil temperature is below
257°F (125°C).
CIRCUIT DIAGRAM
"CHECK TRANS" Circuit Diagram
"CHECK TRANS" INDICATOR TEST CHART

"CHECK TRANS" Indicator Test Chart

Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tires - Proper Inflation Pressure Information
Tires: Technical Service Bulletins Tires - Proper Inflation Pressure Information
Information On Proper Tire Pressure
Affected Vehicles
Service Information
IMPORTANT:
Generally a 5.6°C (10° F) temperature change will result in (is equivalent to) a 1 psi (6.9 kpa) tire
pressure change. Tires may be over inflated from the assembly plant due to the mounting process.
ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on
the vehicles placard during the PRE-DELIVERY INSPECTION.
Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure.
The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct
pressures. The recommended tire inflation pressure is listed on the vehicle's tire placard. The tire
placard is located on the driver's side front or rear door edge, or the rear compartment lid.
Tip
^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 1 psi (6.9 kpa) tire
pressure change.
^ The definition of a "cold" tire is one that has been sitting for at least 3 hours or driven no more
than 1.6 km (1 mi).
IMPORTANT:
Do not use the tire pressure indicated on the tire itself as a guide. Always inspect and adjust the
pressure when the tires are cold. Vehicles that have different pressures for the front and the rear
need to be adjusted after tire rotation.
Improper tire inflation may result in any or all of the following conditions:
^ Premature tire wear
^ Harsh ride
^ Excessive road noise
^ Poor handling
^ Reduced fuel economy
^ Low Tire Pressure Monitor (TPM) Light ON
^ Low Tire Pressure Message on the Drivers Information Center (DIC)

Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service
Bulletins > Tires - Proper Inflation Pressure Information > Page 765
Tires: Technical Service Bulletins Radial Tire - Sidewall Indentations
ISSUE DATE NOVEMBER 1994
GROUP TIRES & WHEELS
RADIAL TIRE SIDEWALL INDENTATIONS
AFFECTED VEHICLES
All Isuzu models equipped with radial tires.
SERVICE INFORMATION
On some affected vehicles, slight indentations may be noticeable on the sidewall surface of one or
more tires, giving the sidewall a wavy appearance.
The cause of these indentations lies in a radial tire's construction. In a radial tire, the body ply cords
run straight across the tire from bead to bead. Because of this "straight across" construction, the
joining of the ply material in the sidewall area may sometimes cause the sidewall surface to
develop slight indentations when the tire is inflated.
These sidewall indentations are a common characteristic of radial tires and will not affect the tire's
performance.
Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments >
Automatic Locking Hub
Wheel Bearing: Adjustments Automatic Locking Hub
Fig. 1 Exploded View Of Automatic Locking Hub Assembly
1. Shift transfer lever to the 2H position then move vehicle forward and rearward approximately
three feet. 2. Raise and support vehicle, then remove wheel and tire assemblies. 3. Remove hub
cap retaining bolts then the hub cap, Fig. 1. 4. Remove housing assembly, snap ring and shims. 5.
Remove drive clutch assembly, inner cam and lock washer. 6. Using a spring scale, adjust bearing
preload to 3.31 lbs. 7. Install lock washer with larger diameter of the tapered bore to the vehicle. If
bolt holes in the lock plate are not aligned with the corresponding
holes in the nut, reverse the lock plate. If bolt holes are still out of alignment, turn nut enough to
obtain alignment. Ensure screw is fastened tightly so head is lower than surface of washer.
Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments >
Automatic Locking Hub > Page 770
Wheel Bearing: Adjustments Manual Locking Hub
Fig. 2 Exploded View Of Manual Locking Hub Assembly
1. Shift transfer lever to the 2H position and set free wheeling hub into FREE position. 2. Raise and
support vehicle, then remove wheel and tire assemblies. 3. Remove housing assembly retaining
bolts then the housing assembly, Fig. 2. 4. Remove snap ring and shims. 5. Remove body
assembly and lock washer. 6. Using a spring scale, adjust bearing preload to 3.03 lbs. 7. Install
lock washer with larger diameter of the tapered bore to the outer side of vehicle. If bolt holes in the
lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate. If bolt holes are still out of alignment, turn nut
enough to obtain alignment. Ensure screw is fastened tightly so head is lower than surface of
washer.
8. Apply Loctite 515 or equivalent, to body assembly and install. 9. Install snap ring and shims, then
adjust clearance between free wheeling hub body and snap ring. Clearance should be 0.01 inch.
Available
adjusting shim are .008, .011, .020 and .039.
10. Align and install cover assembly. Torque bolts to 8.7 ft. lbs.
Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Component ..........................................................................................................................................
........................................................ Torque/Ft. lbs. Auto Locking Hub Nut ........................................
..............................................................................................................................................................
. 76 Axle Nut ........................................................................................................................................
..................................................................................... 76 Driveshaft Nut ...........................................
..............................................................................................................................................................
........... 76 Hub Nut ..............................................................................................................................
................................................................................................ 76 Lower Ball Joint To Knuckle ..........
..............................................................................................................................................................
..................... 94 Lower Ball Joint To Lower Control Arm ....................................................................
....................................................................................................... 76 Lower Control Arm To Frame
(Front Bolt) ...........................................................................................................................................
.......................... 116 Lower Control Arm To Frame (Rear Bolt) ..........................................................
............................................................................................................ 145 Shock Absorber To
Frame ..................................................................................................................................................
............................................... 15 Shock Absorber To Lower Control Arm ..........................................
.................................................................................................................................. 61 Stabilizer Bar
To Stabilizer Link .................................................................................................................................
........................................................ 8 Stabilizer Link To Lower Control Arm ......................................
.......................................................................................................................................... 8 Steering
Knuckle ................................................................................................................................................
........................................................... 72-80 Upper Ball Joint To Knuckle ..........................................
................................................................................................................................................... 73
Upper Ball Joint To Upper Control Arm ...............................................................................................
............................................................................ 24 Upper Control Arm Fulcrum To Frame ..............
.............................................................................................................................................................
113 Upper Control Arm To Fulcrum ....................................................................................................
.................................................................................... 80 Wheel Lug Nuts .........................................
..............................................................................................................................................................
........ [01]
[01] -- Torque steel wheels to 66 ft. lbs., Aluminum wheels to 87 ft. lbs.
Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical
Service Bulletins > Locking Hub - Special Tool
Wheel Hub (Locking): Technical Service Bulletins Locking Hub - Special Tool
GROUP PROPELLER SHAFT & AXLE
LOCKING FRONT HUBS SPECIAL TOOL IDENTIFICATION
AFFECTED VEHICLES
1988-91 Trooper II (KT), 1992-93 Trooper (UX), 1988-93 Pickup (TF) and Amigo (TC), and
1991-93 Rodeo (UC) models equipped with 4-wheel drive.
SERVICE INFORMATION
The locking front hub outer bearing, outer race installer (special tool) is incorrectly identified in
1988-93 Workshop Manuals for affected vehicles.
The correct special tool number for the locking front hub outer bearing, outer race installer is
J-29015.
Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Service
and Repair > Automatic Locking Hub
Wheel Hub (Locking): Service and Repair Automatic Locking Hub
REMOVAL
1. Bolt
Shift the transfer lever to the "2H" position and move the vehicle forward and rearward about one
meter. Remove the 14 mm hex bolts.
2. Hubcap 3. Housing assembly 4. Snap ring and shims 5. Drive clutch assembly 6. Inner cam 7.
Lockwasher
and Repair > Automatic Locking Hub > Page 781
8. Hub nut
Wrench: J-36827
9. Hub and disc assembly
- Before disassembly, remove the disc brake caliper assembly and hang it on the frame with wires
(Refer to "FRONT HUB AND DISC (2WD MODEL)".
10. Outer bearing and outer race 11. Oil seal 12. Inner bearing and outer race
(a) Remove the outer bearing from the hub with fingers. The inner bearing will remain in the hub
and may be removed after prying out the inner
bearing lip seal assembly.
(b) Remove the outer race by driving out the race from the hub with a brass drift inserted behind
the race in the notches in the hubs.
13. Bolt
- If necessary, replace the wheel pin in the following manner.
(a) Apply a scribe mark to disc to hub. (b) Clamp the hub and disc assembly in a vise, using
protective pads. Remove the 6 disc-to-hub retaining bolts.
14 Wheel pin
- Place hub on a suitable work surface and remove the wheel studs, as required, using a hammer.
INSPECTION (VISUAL CHECK)
Inspect the following parts for wear, damage, or other abnormal conditions.
- Hub
- Hub bearing, oil seal
- Knuckle spindle
- Disc
- Caliper
- Automatic locking hubs
For inspection and servicing of disc caliper and relative parts, refer to "DISC BRAKES".
Inside diameter of housing measurement
Inspect flange surface A and B for excessive wear.

Drive clutch section dimensions "L" measurement Hold ring sliding resistance check
Sliding resistance: 6.9 N (5.0 - 22 lb.)
Check the sliding resistance along opening direction as shown in the figure.
Outside diameter of the drive clutch assembly (D) measurement INSTALLATION
14. Wheel pin
(a) Place the hub on a wood workbench or a block of wood approx 6" by 6" to protect the wheel
stud ends and threads.
(b) Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats
completely.
13. Bolt
- Align scribe marks and attach the hub to the disc. Tighten the bolts to the specified torque.
Torque: 103 N.m (76) (lb.ft.)
12. Inner bearing and outer race
- Install the outer race; inner bearing by driving it into the hub.
Installer: J-36829 Grip: J-8092
10. Outer bearing and outer race

- Install the outer race ; outer bearing by driving it into the hub.
11. Oil seal
- Place the inner bearing onto the outer race in the hub and install a new oil seal and retaining ring.
- Apply Multipurpose type grease NLGI No.2 or equivalent to the lip portion
9 Hub and disc assembly
(a) Put grease in the hub.
(b) Apply EP Multipurpose type grease NLGI No.2 or equivalent to the outer and inner bearing.
8. Hub nut
- Turn the place where there is a chamfer in the tapped hole to the outer side, and attach the nut.
Wrench: J-36827
Preload adjustment
Tighten the hub nut at 29.4 N.m (21.7 lb.ft.), then loosen the nut to the full. Tighten the hub nut at
the value given below, using a spring scale on the wheel pin. If the measured bearing preload is
outside the specifications, adjust it by loosening or tightening the bearing nut.
7. Lock washer
- Turn the side with larger diameter of the tapered bore to the vehicle outer side, and attach the
washer. If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut,
reverse the lock plate. If the bolt holes are still out of alignment, turn in the nut just enough to obtain
alignment. Screw is to be fastened tightly so its head may come lower than the surface of the
washer.
6. Inner cam
(a) Before installation, shift the transfer lever to "2H" position.
(b) Clean the flange surface of the hub, the thread holes, the surface of the lock washer and the
spline portion of the axle shaft.
(c) Install the inner cam by aligning the key way of the inner cam with the groove of the knuckle.
NOTE: The cam gear must be facing out.
- If it is difficult to install the inner cam, use the tool (installer) and a plastic hammer or the
equivalent. Install the special tool. Use the plastic hammer to lightly tap around the special tool "A"
surface as shown in the illustration.
Installer: J-38194
NOTE: Do not strike the inner cam gear teeth with the plastic hammer.
Shim selection
(a) Lower vehicle from hoist.

(b) Support lower link with floor jack, placing axle in normal horizontal position.
Fig. 3 Axle Shaft Snap Ring Tool Installation
(c) Install special tool J-36836 to axle shaft with J-36835-2 until it comes into contact with the lock
washer.
Fig. 18 Measuring axle shaft snap ring clearance
(d) Using a feeler gauge, measure clearance "t" between the special tool and the snap ring groove
of the axle shaft.
(e) If clearance "t" is larger than snap ring groove, selected shims must be installed so that
clearance "t" is 0 to 0.1 mm (0 to 0.0039 in)
Thickness shims; 0.2, 0.3, 0.5, 1.0 mm
(f) Remove special tool J-36836, leaving the inner cam in position.
5. Drive clutch assembly
- Apply EP. multipurpose grease NLGI No.2 to the following portions.
(a) Axle shaft splines
Fig. 19 Application of drive clutch assembly lubricant (Part 1 of 2)
- "A" groove and "B" portion

- "C" circumference and "D" portion
(b) Align the cut portion of the drive clutch assembly with the concave portion of inner cam. (c)
Engage the cam teeth of the drive clutch assembly to that of the inner cam by turning the axle
shaft.
4. Snap ring and shims
(a) Install shims (selected above) to axle by hand.
NOTE: Always use a new snap ring.
(b) Install special tool J-36835-2 to axle. (c) Install snap ring to tool. (d) Install tool driver J-36835-1.
(e) Pull out the axle shaft fully by pulling the tool J-36835-2. Install snap ring to axle by pushing on
tool driver J-36B35-1. (f) Remove tool driver J-36835-2 from axle.
Fig. 20 Installation of axle snap rings & shims
NOTE: After installing the shims and the snap ring, check the fitting condition of the snap ring.
3. Housing assembly 2. Hubcap 1. Bolt

(a) Apply Loctite 515 (or the equivalent) to the flange surface of the housing assembly. (b) Make
sure that the housing assembly turns smoothly. If it turns smoothly, the spacer selected above is
correct.
(c) Tighten the bolt to the specified torque.
NOTE: Be sure to attach the spring washer.

Wheel Hub (Locking): Service and Repair Manual Locking Hub
DISASSEMBLY
1. Remove outer bearing, oil seal and inner bearing.
2. While pushing follower knob, turn clutch assembly clockwise and remove clutch assembly from
knob.
3. Remove snap ring, knob, compression spring and follower.
4. Turn clutch assembly retaining spring clockwise and remove from assembly.
5. Remove detent ball and spring.
6. Remove hub lock ring, snap ring, inner assembly, snap ring, ring and spacer.
Fig. 21 Exploded view of manual locking hub.
ASSEMBLY
1. Apply grease to both faces of spacer and install.
2. Apply grease to inside face of ring and install.
3. Install snap ring, then apply grease to splined portion of inner assembly body and install.
4. Install snap ring, hub lock ring, detent ball and spring, Fig. 21.
5. Apply grease to outer circumference of knob and inner circumference of cover.
6. Align detent ball with groove of cover and install knob.

7. Install snap ring with smooth surface toward knob.
8. Install clutch assembly retaining spring.
9. Install follower to clutch. Ensure follower nail comes close to the bent portion of retaining spring
by aligning follower stopper nail to outer teeth of clutch, then hook retaining spring onto upper
portion of hanger nails of follower.
10. Install compression spring with smaller diameter toward follower.
11. Install clutch assembly as follows: a. Align follower nail to handle groove then assemble clutch
with knob by pushing and turning clutch counterclockwise to knob.
12. Using tools J-36828 and J-8092 or equivalent, install two outer races then two outer bearings.
13. Coat hub with grease, then apply Besco L-2 or equivalent to inner and outer bearing.
14. Turn hub so chamfer is aligned to the tapped hole on outer side, then using tool J-36827 or
equivalent, install hub nut.
15. Using a spring scale, adjust bearing preload to 3.03 lbs.
16. Install lock washer with larger diameter of the tapered bore to the outer side of vehicle. If bolt
holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock
plate. If bolt holes are still out of alignment, turn nut enough to obtain alignment. Ensure screw is
fastened tightly so head is lower than surface of washer.
17. Apply Loctite 515 or equivalent, to body assembly and install.
18. Install snap ring and shims, then adjust clearance between free wheeling hub body and snap
ring. Clearance should be 0.01 inch. Available adjusting shim are .008, .011, .020 and .039.
19. Align and install cover assembly torquing bolts to 8.7 ft. lbs.
Wheel Hub (Locking): Service and Repair Removal and Installation
Fig. 15 Exploded view of automatic locking hub assembly
1. Shift transfer lever to the ``2H'' position, then move vehicle forward and rearward approximately
three feet.
2. Raise and support vehicle, then remove wheel and tire assemblies.
3. Disconnect brake hose from caliper.
4. Remove caliper locking bolt.
5. Rotate pad assembly upward then remove pad retaining clip and caliper assembly
6. Remove brake pad support bracket.
7. Remove hub cap retaining bolts, then the hub cap, Fig. 15.
8. Remove housing assembly, snap ring and shims.
9. Remove drive clutch assembly, inner cam and lock washer.
10. Using tool J-36827 or equivalent, remove hub nut.
11. Remove hub and disc assembly.
Fig. 16 Exploded view of manual locking hub assembly

Manual Locking Hub
1. Shift transfer lever to the ``2H'' position and set free wheeling hub into Free position.
7. Remove housing assembly retaining bolts then the housing assembly Fig. 16.
8. Remove snap ring and shims.
9. Remove body assembly and lock washer.

Isuzu Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Wheel Lug - Torque Stick Now Used for Installation
Wheel Fastener: Technical Service Bulletins Wheel Lug - Torque Stick Now Used for Installation
ISSUE DATE: MAY 1999
GROUP: STANDARD TOOLS
3/4" (19 mm) WHEEL LUG TORQUE STICK
AFFECTED VEHICLES
All Isuzu models (exduding Hombre) equipped with 3/4" (19 mm) wheel lug nuts.
ESSENTIAL TOOL INFORMATION
To prevent over-tightening wheel lugs on Isuzu passenger vehicles, American Isuzu Motors Inc. is
making essential a 3/4" (19 mm) wheel lug torque stick. This new tool # J-44342 must now be used
for the installation of steel/aluminum wheels on all Isuzu passenger vehicle wheels, excluding
Hombre MY96-99, I-Mark MY87-89, and P'UP MY87. The torque stick is preset to Isuzu factory
specifications and is an Isuzu essential tool.
Tool number J-44342 will be shipped free of charge to all Isuzu SUV dealerships in June 1999.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System
Diagnosis
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > NHTSA94V132000
> Jul > 94 > Recall 94V132000: Camshaft Seal End Plug Defect
Camshaft: All Technical Service Bulletins Recall 94V132000: Camshaft Seal End Plug Defect
CONSTANT EXPANSION AND CONTRACTION OF THE CYLINDER HEAD CAUSES THE
CAMSHAFT SEAL END PLUG CAN BECOME DISLODGED FROM THE CYLINDER HEAD. THIS
ALLOWS OIL TO LEAK FROM THE CAMSHAFT. THIS CAN CAUSE ENGINE DAMAGE AND
POSSIBLE ENGINE FIRE FROM OIL LEAKING ONTO THE HOT EXHAUST SYSTEM. DEALERS
WILL INSTALL CAMSHAFT END SEAL PLUG RETAINER PLATES.
SYSTEM: ENGINE; CAMSHAFT.
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES EQUIPPED WITH ISUZU

6VDI ENGINES.
NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED

UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME
AND FREE OF CHARGE, OR THE REMEDY DOES NOT CORRECT THE DEFECT OR
NON-COMPLIANCE, PLEASE CONTACT ISUZU SERVICE CENTER AT 1-800-255-6727 OR
HONDA SERVICE CENTER AT 1-800-999-1009. ALSO, CONTACT THE NATIONAL HIGHWAY
TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
1992 ISUZU TRUCK TROOPER 1993 ISUZU TRUCK RODEO 1993 ISUZU TRUCK TROOPER
1994 HONDA TRUCK PASSPORT 1994 ISUZU TRUCK RODEO 1994 ISUZU TRUCK TROOPER
> Component Information > Technical Service Bulletins > Recalls for Camshaft: > NHTSA94V132000 > Jul > 94 > Recall
94V132000: Camshaft Seal End Plug Defect
Camshaft: Recalls Recall 94V132000: Camshaft Seal End Plug Defect
CONSTANT EXPANSION AND CONTRACTION OF THE CYLINDER HEAD CAUSES THE
CAMSHAFT SEAL END PLUG CAN BECOME DISLODGED FROM THE CYLINDER HEAD. THIS
ALLOWS OIL TO LEAK FROM THE CAMSHAFT. THIS CAN CAUSE ENGINE DAMAGE AND
POSSIBLE ENGINE FIRE FROM OIL LEAKING ONTO THE HOT EXHAUST SYSTEM. DEALERS
WILL INSTALL CAMSHAFT END SEAL PLUG RETAINER PLATES.
SYSTEM: ENGINE; CAMSHAFT.
VEHICLE DESCRIPTION: MULTI-PURPOSE PASSENGER VEHICLES EQUIPPED WITH ISUZU

6VDI ENGINES.
NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED

UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED WITHIN A REASONABLE TIME
AND FREE OF CHARGE, OR THE REMEDY DOES NOT CORRECT THE DEFECT OR
NON-COMPLIANCE, PLEASE CONTACT ISUZU SERVICE CENTER AT 1-800-255-6727 OR
HONDA SERVICE CENTER AT 1-800-999-1009. ALSO, CONTACT THE NATIONAL HIGHWAY
TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393.
1992 ISUZU TRUCK TROOPER 1993 ISUZU TRUCK RODEO 1993 ISUZU TRUCK TROOPER
1994 HONDA TRUCK PASSPORT 1994 ISUZU TRUCK RODEO 1994 ISUZU TRUCK TROOPER
> Component Information > Specifications > Service Specifications
Camshaft: Specifications Service Specifications
Camshaft Journal Diameter .................................................................................................................

................................................. 1.7692-1.7701 inches Maximum Journal Runout ..............................
.................................................................................................................................................. 0.0039
inches Camshaft Bearing Clearance ...................................................................................................
............................................................. 0.0016-0.0043 inches Camshaft Endplay ..............................
..................................................................................................................................................
0.0028-0.0079 inches
> Component Information > Specifications > Service Specifications > Page 821
Camshaft: Specifications Camshaft Bearing Brackets
M6 Bolts ...............................................................................................................................................
................................................... 8 Nm (69 inch lbs.) M8 Bolts ...........................................................
........................................................................................................................................ 18 Nm (13 ft.
lbs.)
Camshaft: Service and Repair
1. Relieve fuel system pressure as outlined under Technician Safety Information. On models with
airbag system, refer to Technician Safety
Information for system disarming and arming procedures.
2. Disconnect battery ground cable, then insulate cable end with electrical tape, or equivalent. 3.
Remove air cleaner assembly. 4. Remove upper and lower radiator fan shroud from radiator. 5.
Remove cooling fan assembly, then disconnect accelerator cable from throttle body. 6. Mark
position of vacuum hoses for installation, then remove from common chamber and throttle body. 7.
Mark position of electrical connectors for installation, then disconnect connectors from common
chamber. 8. Disconnect spark plug wires from valve covers, then the three electrical connectors
from DIS module. 9. Remove DIS module and spark plug wires as an assembly.
10. Remove EGR valve assembly, then the common chamber. 11. Disconnect fuel supply and
return hoses from fuel rail assembly. 12. Remove drive belts, then power steering pump. Do not
disconnect pressure lines from power steering pump. 13. Remove fan pulley assembly, then the
timing belt. 14. Remove valve cover, then the camshaft pulley. 15. Remove front plate, then the
camshaft retaining bracket. 16. Remove camshaft, then the rocker arm assembly.
Fig. 47 Rocker Arm Assembly Tightening Sequence
17. Reverse procedure to install, noting the following:
a. Using sequence shown in Fig. 47, torque rocker arm assembly retaining bolts to 13 ft. lbs. b.
Torque camshaft bracket retaining bolt M8 to 13 ft. lbs., then the camshaft bracket retaining bolt M6
to 6 ft. lbs. c. Tighten front plate retaining bolts to specification. d. Tighten camshaft pulley retaining
bolts to specification.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 >
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Engine Valve Train - Ticking Noise > Page 831
Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Adjuster, Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lifter / Lash
Adjuster: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Adjuster: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 840
Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr..
Lifter / Lash Adjuster: All Technical Service Bulletins Trooper(UX) & Rodeo(UC) SOHC Hydraulic
Valve Lifter Pr..
ISSUE DATE SEPTEMBER 1995
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) SOHC HYDRAULIC VALVE LIFTER PRIMING (Supersedes
SB95-01-L003)
AFFECTED VEHICLES
SERVICE INFORMATION
Hydraulic valve lifters on 6VD1 SOHC engines are self-bleeding. However, when a lifter is
replaced, it should be primed (i.e., filled with oil and purged of excess air) before it is reinstalled into
its rocker arm, to minimize initial valve noise and ensure proper operation. This Service Bulletin
addresses the priming of a replacement SOHC hydraulic valve lifter.
REMOVAL
1. Hydraulic Valve Lifter and Rocker Arm -
Remove old hydraulic valve lifter and rocker arm in accordance with appropriate Workshop Manual.
- Carefully separate new hydraulic valve lifter from its rocker arm.
INSTALLATION
1. Hydraulic Valve Lifter and Rocker Arm
- Push in check ball on underside of lifter, using small diameter rod (2 mm/.O8 in), and submerge
new lifter in clean engine oil. Be sure to wear suitable gloves to protect hands from engine oil.
- Pump plunger (located on top of lifter) to fill lifter with oil and purge it of excess air. Keep pumping
plunger until no air bubbles are visible in engine oil and plunger becomes hard.
- When no air bubbles are visible, and the plunger is hard, remove the rod to release the check
ball.
IMPORTANT: Each hydraulic valve lifter and rocker arm are an integrated set. Do not mix these
parts during reinstallation.
Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. > Page 848
- Submerge new rocker arm in clean engine oil and install primed lifter into rocker arm.
- Remove assembly from engine oil and install onto rocker arm shaft in accordance with
appropriate Workshop Manual.
FLAT RATE MANUAL INFORMATION
Use existing Flat Rate Manual labor operation number 010247 (right side) or 01A247 (left side).
Adjuster, Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Lifter / Lash
Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr..
Lifter / Lash Adjuster: All Technical Service Bulletins Trooper(UX) & Rodeo(UC) SOHC Hydraulic
Valve Lifter Pr..
ISSUE DATE SEPTEMBER 1995
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) SOHC HYDRAULIC VALVE LIFTER PRIMING (Supersedes
SB95-01-L003)
AFFECTED VEHICLES
SERVICE INFORMATION
Hydraulic valve lifters on 6VD1 SOHC engines are self-bleeding. However, when a lifter is
replaced, it should be primed (i.e., filled with oil and purged of excess air) before it is reinstalled into
its rocker arm, to minimize initial valve noise and ensure proper operation. This Service Bulletin
addresses the priming of a replacement SOHC hydraulic valve lifter.
REMOVAL
1. Hydraulic Valve Lifter and Rocker Arm -
Remove old hydraulic valve lifter and rocker arm in accordance with appropriate Workshop Manual.
- Carefully separate new hydraulic valve lifter from its rocker arm.
INSTALLATION
1. Hydraulic Valve Lifter and Rocker Arm
- Push in check ball on underside of lifter, using small diameter rod (2 mm/.O8 in), and submerge
new lifter in clean engine oil. Be sure to wear suitable gloves to protect hands from engine oil.
- Pump plunger (located on top of lifter) to fill lifter with oil and purge it of excess air. Keep pumping
plunger until no air bubbles are visible in engine oil and plunger becomes hard.
- When no air bubbles are visible, and the plunger is hard, remove the rod to release the check
ball.
IMPORTANT: Each hydraulic valve lifter and rocker arm are an integrated set. Do not mix these
parts during reinstallation.
Adjuster, Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Lifter / Lash
Adjuster: > SB95-01-L006 > Sep > 95 > Trooper(UX) & Rodeo(UC) SOHC Hydraulic Valve Lifter Pr.. > Page 854
- Submerge new rocker arm in clean engine oil and install primed lifter into rocker arm.
- Remove assembly from engine oil and install onto rocker arm shaft in accordance with
appropriate Workshop Manual.
Use existing Flat Rate Manual labor operation number 010247 (right side) or 01A247 (left side).
Adjuster, Valve > Component Information > Technical Service Bulletins > Page 855
Lifter / Lash Adjuster: Testing and Inspection

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
Tighten rocker arm shafts bolts in sequence (13 lb ft.)

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Testing and Inspection
Connecting Rod: Testing and Inspection
CONNECTING RODS
1. Check the connecting rod alignment with a connecting rod alignment tool (Fig 6A-120) If either
the bend or the twist exceeds the specified limit,
the connecting rod must be replaced.
2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust
clearance at the big end of the connecting rod (Fig. 6A-121).
If the clearance exceeds the specified limit, the connecting rod must be replaced.
3. Measure the oil clearance between the connecting rod and the crankshaft by:
1) Remove the connecting rod cap nuts and the rod caps. Arrange the removed rod caps in the
cylinder number order. 2) Clean the rod bearings and the crankshaft pins. 3) Carefully check the
rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing
assembly must be replaced as a
set. Reinstall the bearings in their original positions. Apply plastigage to the crank pin (Fig. 6A-122).
4) Reinstall the rod caps to their original positions.

Component Information > Testing and Inspection > Page 863
TIGHTEN THE ROD CAPS. (6VD1)
Torque: N.m (lb.ft) 54 (40)
NOTE: Do not allow the crankshaft to rotate.
5) Remove the rod caps. 6) Measure the width of the plastigage and determine the oil clearance. It
the oil clearance exceeds the limit, replace the rod bearing as a set (Fig.
6A-123).
7) Clean the plastigage from the bearings and the crankshaft pins.
CON-ROD BEARING SELECTION (Fig. 6A-124)

Select the install the new connecting rod bearings, paying close attention to the connecting rod big
end diameter size mark.
NOTE: Take care not to confuse the alignment mark and the size mark during the installation
procedure.
Component Information > Service and Repair > Disassembly and Assembly
Connecting Rod: Service and Repair Disassembly and Assembly
CONNECTING RODS
1. Check the connecting rod alignment with a connecting rod alignment tool (Fig 6A-120) If either
the bend or the twist exceeds the specified limit,
the connecting rod must be replaced.
2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust
clearance at the big end of the connecting rod (Fig. 6A-121).
If the clearance exceeds the specified limit, the connecting rod must be replaced.
3. Measure the oil clearance between the connecting rod and the crankshaft by:
1) Remove the connecting rod cap nuts and the rod caps. Arrange the removed rod caps in the
cylinder number order. 2) Clean the rod bearings and the crankshaft pins. 3) Carefully check the
rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing
assembly must be replaced as a
set. Reinstall the bearings in their original positions. Apply plastigage to the crank pin (Fig. 6A-122).
4) Reinstall the rod caps to their original positions.

Component Information > Service and Repair > Disassembly and Assembly > Page 866
TIGHTEN THE ROD CAPS. (6VD1)
NOTE: Do not allow the crankshaft to rotate.
5) Remove the rod caps. 6) Measure the width of the plastigage and determine the oil clearance. It
the oil clearance exceeds the limit, replace the rod bearing as a set (Fig.
6A-123).
7) Clean the plastigage from the bearings and the crankshaft pins.
CON-ROD BEARING SELECTION (Fig. 6A-124)

Select the install the new connecting rod bearings, paying close attention to the connecting rod big
end diameter size mark.
NOTE: Take care not to confuse the alignment mark and the size mark during the installation
procedure.
Component Information > Service and Repair > Disassembly and Assembly > Page 867
Connecting Rod: Service and Repair Piston and Connecting Rod
Fig. 53 Piston & connecting rod assembly
Assemble piston to piston rod as shown in Fig. 53.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Crankshaft: Specifications
Crankshaft:
Standard Journal Diameter:
Main Bearing .......................................................................................................................................

................................ 2.5165-2.5170 inches Crank Pin ........................................................................
..................................................................................................... 2.1229-2.1235 inches
Out Of Round, All ................................................................................................................................

.................................................. 0.0002 inches Taper, All ...................................................................
............................................................................................................................ 0.0002 inches
Endplay ................................................................................................................................................
...................................... 0.0020-0.0090 inches
Crankshaft: Service and Repair
DISASSEMBLY
1. Cylinder head assembly 2. Oil pan
Note: Do not to damage or deform the sealing flange surface of oil pan.
3. Oil pipe and rubber ring 4. Oil strainer and rubber ring 5. Oil pump assembly 6. Crankcase side
bolts 7. Oil gallery 8. Piston and connecting rod assembly 9. Flywheel
10. Rear oil seal retainer 11. Main bearing cap 12. Crankshaft
INSPECTION AND REPAIR
Crankshaft
- Thrust clearance - set the dial indicator as shown in the illustration and measure the crankshaft
thrust clearance.
- If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set.
Crankshaft Inspection
- Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear and damage.
- Inspect the ports for obstructions
1. Carefully set the crankshaft on the V-blocks. Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the specified
limit, the crankshaft must be replaced (Fig. 6A-70).
2. Measure the diameter and the uneven wear of the main journal and crankpin (Fig. 6A-71). If the
crank wear exceeds the specified limit, replace
crankshaft.
Main Bearing Clearance
1. Remove the bearing caps and measure the oil clearance.

2. Remove the main bearing caps in the sequence shown in the illustration (Fig. 6A-72). Arrange
the removed main bearing caps in the cylinder
number order.
3. Remove the crankshaft. Remove the main bearings. 4. Clean the upper and lower bearings as
well as the crankshaft main journal. 5. Check the bearings for damage or excessive wear. The
bearings must be replaced as a set if damage or excessive wear is discovered during
inspection.
6. Set the upper bearings and the thrust washers to their original positions. Carefully install the
crankshaft. 7. Set the lower bearings to the bearing cap original position.
8. Apply plastigage to the crankshaft journal unit as shown in the illustration (Fig. 6A-73).
Note: Do not set the plastigage on the oil hole.
9. Install main bearing caps, oil gallery and crank case bolts in the order shown, and tighten each
bolt to the specified torque (Fig. 6A-74).
Note: Do not Apply engine oil to the crank case side bolts.
- Main bearing caps bolts torque N.m (lb.ft) 39 (29)
- Oil gallery fixing bolts: 1st step N.m (lb.ft) 29 (22) 2nd step 55° - 65°
- Crank case side bolts torque N.m (lb.ft) 39 (29)
Note: Do not allow the crankshaft to rotate.
10. Remove the main bearing caps.

11. Measure the plastigage width and determine the oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a set
and/or replace the crankshaft (Fig. 6A-75).
12. Clean the plastigage from the bearings and the crankshaft. Remove the crankshaft and the
bearings.
CRANKSHAFT BEARING SELECTION
- When installing new crankshaft bearings or replacing bearings, refer to the selection table below.
- Select and install the new crankshaft bearings, paying close attention to the cylinder body journal
hole (1) diameter size mark and the crankshaft journal (2) diameter size mark (Fig. 6A-77, Fig.
6A-79).
Note: Take care to ensure the bearings are positioned correctly. (Fig. 6A-82)
REASSEMBLY
12. Crankshaft
- Install the main bearings to the cylinder body and the main bearing caps.
- Be sure that they are positioned correctly (Fig. 6A-83).
- Apply new engine oil to the upper and lower main bearing faces.
- Carefully mount the crankshaft.
- Apply engine oil to the thrust washer.

- Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft
(Fig. 6A-84).
11. Main bearing cap
- Apply engine oil to the threads and the seating faces of the bolts.
- Install bearing caps in the order shown with the No.1 as the front most bearing cap (Fig. 6A-85).
- Semi-tighten all of the bolts.
- Finally, tighten all the bolts to specification in the order shown (Fig. 6A-86). Torque N.m (lb.ft) 39
(29)
- After the final tightening, check to see that the crankshaft rotates smoothly.
10. Rear oil seal
- Remove the oil from the cylinder block and the retainer mounting surface.
- Apply sealant (TB-1207B) or equivalent) to the retainer mounting surface, as shown in the
illustration (Fig. 6A-87).
- Apply engine oil to the oil seal lip.
- Align the cylinder body dowel pin holes with the rear retainer dowel pins.
- Tighten the rear retainer fixing bolts. New bolts should be used when installing rear retainer.
Torque N.m (lb.ft) 18 (13)
Note: Be very careful not to disengage the oil seal garter spring during installation of the rear
retainer. If the seal was removed from retainer for replacement, apply engine oil to the oil seal lip
and install the oil seal using installer (Fig. 6A-88). Installer; J-39201
9. Flywheel
1) Thoroughly clean and remove the oil from the threads of crankshaft. 2) Remove the oil from the
crankshaft and flywheel mounting faces. 3) Mount the flywheel on the crankshaft and then install
the washer.
4) Holding the crankshaft to prevent from rotating, tighten bolts in the order shown to the specified
torque (Fig. 6A-89). Torque N.m (lb.ft) 54
(40)
Note: Do not reuse the bolts. Do not apply the oil or thread lock to the bolts.
8. Piston and connecting rod assembly
- Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins.
- Check to see that the piston ring end gaps are correctly positioned (Fig. 6A-90).
- Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor.
- The front marks must be facing the front of the engine (Fig. 6A-91).
- Match the numbered caps with the numbers on the connecting rods. Align the punched marks on
the connecting rods and caps.
- Apply engine oil to the threads and seating faces of the nuts. Tighten the nuts torque N.m (lb.ft)
54 (40)
- After tightening the cap nuts, check to see that the crankshaft rotates smoothly.
7. Oil gallery
- Tighten the bolts in 2 steps, in the order shown (Fig. 6A-92).
- 1st step N.m (lb.ft) 29 (22) 2nd step 55° - 65°
6. Crankcase side bolts

- Tighten all the bolts to specification in the order shown (Fig. 6A-93). Torque N.m (lb.ft) 39 (29)
Note: Do not apply engine oil to the crankcase side bolts.
5. Oil pump assembly 4. Oil strainer and rubber ring 3. Oil pipe and rubber ring
- Tighten the bolts Torque N.m (lb.ft) 19 (14)
2. Oil pan
1) Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2) Apply a correct width bead of sealant (TB-1207C or its equivalent) to the contact surfaces of the
oil pan. There must be no gaps in the bead
(Fig. 6A-94).
3) The oil pan must be installed within 30 minutes after sealant application. 4) Tighten the bolts and
nuts to the specified torque N.m (lb.in) 10 (87)
1. Cylinder head assembly

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer -
Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Camshaft Pulley Retaining Bolts 41 ft.lb
Crankshaft Pulley 123 ft.lb

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Piston: Specifications
Piston Diameter ...................................................................................................................................

............................................................................ [01] Piston Clearance .............................................
.................................................................................................................................................... 0.004
inches Piston Pin Diameter .................................................................................................................
............................................................ 0.8660-0.8650 inches Piston Pin To Piston Clearance
............................................................................................................................................................
0.0008-0.0016 inches Piston Ring End Gap:
Comp. ..................................................................................................................................................
.................................................................. [02] Oil ..............................................................................
................................................................................................................ 0.0059-0.0177 inches
Piston Ring Side Clearance:
Comp. ..................................................................................................................................................
...................................... 0.0010-0.0026 inches
[01] -- Piston grade (A), 3.6752-3.6756 inches; (B) 3.6756-3.6760 inches; (C) 3.6760-3.6764
inches. [02] -- Top compression ring, 0.00138-0.0185 inch; second ring, 0.0177-0.0236 inch.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Piston: Service and Repair
Fig. 53 Piston & connecting rod assembly
Assemble piston to piston rod as shown in Fig. 53.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Piston Pin: Specifications
Piston Diameter ...................................................................................................................................

............................................................................ [01] Piston Clearance .............................................
.................................................................................................................................................... 0.004
inches Piston Pin Diameter .................................................................................................................
............................................................ 0.8660-0.8650 inches Piston Pin To Piston Clearance
............................................................................................................................................................
0.0008-0.0016 inches Piston Ring End Gap:
Comp. ..................................................................................................................................................
.................................................................. [02] Oil ..............................................................................
................................................................................................................ 0.0059-0.0177 inches
Piston Ring Side Clearance:
Comp. ..................................................................................................................................................
...................................... 0.0010-0.0026 inches
[01] -- Piston grade (A), 3.6752-3.6756 inches; (B) 3.6756-3.6760 inches; (C) 3.6760-3.6764
inches. [02] -- Top compression ring, 0.00138-0.0185 inch; second ring, 0.0177-0.0236 inch.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
> Engine Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > Page 912
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
GROUP: ENGINE
NOTE:

AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION
Service Procedure

NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Stem Diameter:
Intake ...................................................................................................................................................
...................................... 0.2346-0.2323 inches Exhaust .....................................................................
................................................................................................................. 0.2343-0.2323 inches

............................................................................... 45 Valve Clearance:
Intake ...................................................................................................................................................
.................................................................. [01] Exhaust ......................................................................
............................................................................................................................................ [01]


Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions
following items:
lubricated.)
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 927
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Rocker Arm Assembly: Specifications
Tighten rocker arm shafts bolts in sequence (13 lb ft.)

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Technical Service Bulletins > Cylinder Head Cover - Installation Precautions
Valve Cover: Technical Service Bulletins Cylinder Head Cover - Installation Precautions
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) CYLINDER HEAD COVER DAMAGE
AFFECTED VEHICLES
Trooper (UX) and Rodeo (UC) models equipped with 6VDl engine.
SERVICE INFORMATION
When reinstalling cylinder head covers on affected vehicles, care must be taken to ensure that the
head cover bolts are properly tightened. Use only a good quality torque wrench and tighten only to
the specifications listed in the appropriate Workshop Manual. Do not use air impact wrenches to
tighten cylinder head cover bolts. Air wrenches tighten the bolt until the corner tab on the cylinder
head cover either cracks or breaks (Figure 1). Once the tab is damaged, an oil leak will result. This
damage can be incorrectly diagnosed as a leaking head gasket or a rear main oil seal. Cracked or
broken cylinder head covers due to over tightening are not covered under warranty.
Information > Service and Repair > Left Hand Side
Valve Cover: Service and Repair Left Hand Side
REMOVAL
Preparation: Remove battery ground cable
1. Ignition wire
- Disconnect from spark plug side.
2. Positive Crankcase Ventilation hose and Vacuum hose
- Disconnect from common chamber.
- Disconnect vacuum hose from throttle body.
3. Engine harness bracket
- Remove fixing bolts on cylinder head cover.
4. Exhaust Gas Recirculation (EGR) pipe
- Remove fixing bolts on cylinder head cover.
- Remove two fixing bolts on exhaust manifold.
- Remove flange nut on EGR valve pipe.
5. Cylinder head cover
- Remove 11 fixing bolts then the cylinder head cover.
INSTALLATION
Information > Service and Repair > Left Hand Side > Page 937
Fig. 6A1-3
See TSB SB94-01-003 12-94
- Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing
materials completely. Apply sealant (TB-1207b or equivalent) of bead diameter 2- 3 mm at four
places of arched area of camshaft brackets on front and rear sides (Fig.6A1-3).
- Tighten cylinder head cover bolts to the specified torque above.
4. Exhaust Gas Recirculation (EGR) pipe. Tighten each fixing bolt to the specified torque above. 3.
Engine harness bracket 2. Positive Crankcase Ventilation hose and vacuum hose 1. Ignition wire
Valve Cover: Service and Repair Right Hand Side
REMOVAL
Preparation: Remove battery ground Gable
1. Common chamber See: Intake Manifold/Service and Repair 2. Ventilation hose
- Disconnect from cylinder head cover.
3. Fuel hose
- Disconnect feed and return hoses from fuel pipes.
- Remove two fuel hose fixing bolts on the cylinder head cover.
4. Engine hanger
- Remove heat protector on exhaust manifold.
- Remove bolts and nuts that secure the hanger to the exhaust manifold and cylinder head.
5. Heater pipe
- Remove heater pipe fixing bolts from the bracket.
- Remove 11 fixing bolts, then the cylinder head cover.
INSTALLATION
See TSB SB94-01-003 12-94
- Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing
materials completely. Apply sealant (TB-12O7B
or equivalent) of bead diameter 2- 3 mm to four places of arched area of camshaft brackets on

front and rear sides. (Fig. 6A1-5)
- Tighten Cylinder head cover bolts to torque of N.m (lb.in) 8 (69)
5. Heater pipe
Bolt Torque
- Tighten bolts to the specified torque above.
4. Engine hanger.
Bolt Torque
Bolt
Nut Torque
Nut
- Tighten bolts and nuts to the specified torque above.
3. Fuel hose 2. Ventilation hose 1. Common chamber

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications > Cylinder Head, Valve Guides & Valve Seats
Valve Guide: Specifications Cylinder Head, Valve Guides & Valve Seats
Cylinder Head Warpage Limit ..............................................................................................................

............................................................. 0.006 inches Valve Guides:
Stem To Guide Clearance:
Intake ...................................................................................................................................................
................................ 0.2346-0.2323 inches Exhaust ...........................................................................
..................................................................................................... 0.2343-0.2323 inches
Valve Seats:
Seat Width:
Intake ...................................................................................................................................................
.................................... 0.044-0.025 inches Exhaust ...........................................................................
......................................................................................................... 0.044-0.025 inches
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications > Cylinder Head, Valve Guides & Valve Seats > Page 944
Valve Guide: Specifications Valve Clearance Specifications
Stem Diameter:
Intake ...................................................................................................................................................
...................................... 0.2346-0.2323 inches Exhaust .....................................................................
................................................................................................................. 0.2343-0.2323 inches

............................................................................... 45 Valve Clearance:
Intake ...................................................................................................................................................
.................................................................. [01] Exhaust ......................................................................
............................................................................................................................................ [01]

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Valve Seat: Specifications
Cylinder Head Warpage Limit ..............................................................................................................

............................................................. 0.006 inches Valve Guides:
Stem To Guide Clearance:
Intake ...................................................................................................................................................
................................ 0.2346-0.2323 inches Exhaust ...........................................................................
..................................................................................................... 0.2343-0.2323 inches
Valve Seats:
Seat Width:
Intake ...................................................................................................................................................
.................................... 0.044-0.025 inches Exhaust ...........................................................................
......................................................................................................... 0.044-0.025 inches
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Valve Spring: Specifications
Free Length .........................................................................................................................................

............................................................... 1.913 inches Installed Height ..............................................
...................................................................................................................................................... 1.54
inches Compressed Pressure Pounds, Inch Lbs. ................................................................................
............................................................................... 45 @ 1.54 Out Of Square Limit ...........................
..............................................................................................................................................................
.. 0.087 inches
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Valve: Specifications
Stem Diameter:
Intake ...................................................................................................................................................
...................................... 0.2346-0.2323 inches Exhaust .....................................................................
................................................................................................................. 0.2343-0.2323 inches

............................................................................... 45 Valve Clearance:
Intake ...................................................................................................................................................
.................................................................. [01] Exhaust ......................................................................
............................................................................................................................................ [01]

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 9301005 > May > 93 >
Alternator Belt - Squeaking Noise
Drive Belt: Customer Interest Alternator Belt - Squeaking Noise
ISSUE DATE May 1993
GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
3.2L V6 engine are:

Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 9301005 >
May > 93 > Alternator Belt - Squeaking Noise
Drive Belt: All Technical Service Bulletins Alternator Belt - Squeaking Noise
ISSUE DATE May 1993
GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
3.2L V6 engine are:

Belt > Component Information > Technical Service Bulletins > Page 968
Drive Belt: Specifications
CAUTION: ^
It is strongly advised to use a tension gauge to check the tension of this belt. Checking tension by
"feel" of belt is not accurate. Tension should be checked using a tension gauge after installation
and break-in (about 1,000 km or 620 miles).
^ Tension readjustment of auto tension belt should be made only once when V-type HM' tension
has dropped to 40 lb or less and poly V type's to 50 lb or less after the vehicle's total running
mileage of 621 miles.
^ As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge.
Depress belt with 98N (22 lb) and make sure that slackness is in the range of 8 - 12mm (0.315
0.472 in).
Belt tension range to be targeted for cold setting. using a Borrough drive belt tension gauge.
Fixing bolt
Lock bolt
Drive Belt: Testing and Inspection
INSPECTION
Check drive belts for wear or damage, and replace with new ones as necessary. Check belts for
tension, and adjust as necessary.
CAUTION: It is strongly advised to use a tension gauge to check the tension of this belt. Checking
tension by "feel" of belt is not accurate. Tension should be checked using a tension gauge after
installation and break-in (about 1,000 km or 620 miles). Tension readjustment of auto tension belt
should be made only once when V-type HM' tension has dropped to 40 lb or less and poly V type's
to 50 lb or less after the vehicle's total running mileage of 621 miles. ^
As for air conditioning (A/C) compressor driving belt, it is difficult to use a belt tension gauge.
Depress belt with 98N (22 lb) and make sure that slackness is in the range of 0.315 0.472 in.
Belt tension range to be targeted for cold setting. Using a Borrought drive belt tension gauge.
Drive Belt: Adjustments
Fixing bolt
Lock bolt
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Left Side
Engine Mount: Service and Repair Left Side
disarming and arming procedures. 2. Disconnect battery ground cable, then slightly raise and
support engine. 3. Remove engine mount nut from bracket. 4. Remove engine mount bolts and
nuts from chassis. 5. Remove engine mount. 6. Reverse procedure to install. Tighten to
specifications. 7. On models equipped with airbag system, refer to Technician Safety Information
for system disarming and arming procedures.
Engine Mount > Component Information > Service and Repair > Left Side > Page 975
Engine Mount: Service and Repair Right Side
disarming and arming procedures. 2. Disconnect battery ground cable, then raise and support
vehicle. 3. Slightly raise engine and support with suitable jack, to remove weight from engine
mounts. 4. Remove engine mount nut from bracket. 5. Remove wiring harness bracket attaching
bolt, then the engine mount bolts and nuts. 6. Remove engine mount. 7. Reverse procedure to
install. Tighten to specifications. 8. On models equipped with airbag system, refer to Technician
Safety Information for system disarming and arming procedures.
Engine Mount > Component Information > Service and Repair > Left Side > Page 976
Engine Mount: Service and Repair Rear
disarming and arming procedures. 2. Disconnect battery ground cable, then raise and support
vehicle. 3. Remove crossmember mounting nuts. 4. Raise transmission slightly for clearance
between crossmember and transmission, then remove transmission support bolts and nuts. 5.
Remove rear mount. 6. Reverse procedure to install. Tighten to specifications. 7. On models
equipped with airbag system, refer to Technician Safety Information for system disarming and
arming procedures.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Engine Oil Pressure: Specifications
Oil pressure:
.................................................................................................................................................. 392 -
550 kPa (56.9 - 80.4 psi) at 3000 rpm.
(Normal operating temperature of about 80°C (176°F).)

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Engine Oil Pressure: Testing and Inspection
1. Check for dirt, gasoline or water in the engine oil.
a. Change the oil if dirt, gasoline, or water are present. b. Check the viscosity of the oil. c. Change
the oil if the viscosity is outside the specified standard. d. Refer to the Engine Lubrication.
2. Check the engine oil level.
- The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level
dipstick.
- If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit. 4. Install an oil pressure gage. 5. Start the engine and allow the
engine to reach normal operating temperature about 80°C (176°F). 6. Measure the oil pressure. Oil
pressure should be: 392 - 550 kPa (56.9 - 80.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the
oil pressure gage. 9. Install the oil pressure unit.
10. Start the engine and check for leaks.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 >
Engine - Oil Usage Testing and Reporting
SB04-01-S004)
Affected Vehicles
Service Information
Engine - Oil Usage Testing and Reporting > Page 990
PROCEDURE # 2.
NOTE:

engines.
Oil Consumption
km).
IMPORTANT:
IMPORTANT:
IMPORTANT:

Engine Temperature
Engine Wear
oil consumption.
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil: > SB00-01-S009 > Sep > 00 >
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Information > Technical Service Bulletins > Customer Interest: > SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking
Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Noise > Page 1009
Service Procedure
NOTE:
Noise > Page 1010
(Figure 4)
IMPORTANT:
Noise > Page 1011
6)
Noise > Page 1012
compress).
NOTE:
Information > Technical Service Bulletins > All Other Service Bulletins for Engine Oil: > SB07-01-S001 > Jan > 07 > Engine
- Oil Usage Testing and Reporting
SB04-01-S004)
Affected Vehicles
Service Information
- Oil Usage Testing and Reporting > Page 1018
PROCEDURE # 2.
NOTE:

engines.
Oil Consumption
km).
IMPORTANT:
IMPORTANT:
IMPORTANT:

Engine Temperature
Engine Wear
oil consumption.
Disclaimer
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil Refill, quarts including filter ................................................................................................

........................................................................... 5.7
Information > Specifications > Capacity Specifications > Page 1026
Engine Oil: Fluid Type Specifications
Oil Viscosity
Engine Oil Type ......................................... SG, SF, SE/CC or SE Engine Oil

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Information > Technical Service Bulletins > Oil Cooler - Center Bolt Torque Value Correction
Oil Cooler: Technical Service Bulletins Oil Cooler - Center Bolt Torque Value Correction
ISSUE DATE JUNE 1995
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) OIL COOLER CENTER BOLT TORQUE SPECIFICATION
AFFECTED VEHICLES
1992-95 Trooper (UX) and 1993-95 Rodeo (UC) models equipped with 6VD1 engine.
SERVICE INFORMATION
The torque specification for the 6VD1 engine oil cooler center bolt is incorrectly listed as 26 Nm (20
ft.lb.) in the Workshop Manuals:
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Information > Technical Service Bulletins > Oil Cooler - Center Bolt Torque Value Correction > Page 1031
The correct specification should be 59 Nm (43 ft.lb.) (see shaded area of the page). Ensure this
specification is corrected in the referenced Workshop Manual pages.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal
Oil Pan: Service and Repair Removal
NOTE: Before starting, perform the following:
^ Disconnect battery ground cable.
^ Drain engine oil.
^ Lift vehicle by supporting the frame.
^ Remove front wheels.
1. Oil level dipstick
- Remove a dip stick from level gage tube.
2. Stone guard 3. Radiator under fan shroud 4. Suspension crossmembers
- Remove fixing bolts, 2 pieces each per side.
5. Flywheel dust cover 6. Pitman arm and idler arm

- Use the special tool J-29107, or equivalent to remove pitman arm from the steering unit.
- Remove four fixing bolts four idler arm.
7. Axle housing assembly
- Remove two bolts and nuts from housing isolators on both sides.
NOTE: At this time, raise and support the axle with a garage jack.
8. Oil pan fixing bolts and nuts

Information > Service and Repair > Removal > Page 1036
9. Oil pan
- Using sealer cutter, remove oil pan using the sealer cutter J-37228, or equivalent.
CAUTION: Do not deform or damage the flange of oil pan. Replace the oil pan if deformed or
damaged.
Oil Pan: Service and Repair Installation
1. Oil pan [9]
- Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly.
- Apply a properly wide bead of sealant (TB 1207C or equivalent) to mounting surface of oil pan.
Sealant bead must be continuous.
- Oil pan must be installed within 5 minutes after sealant is applied.
2. Oil pan fixing bolts and nuts [8]
- Tighten oil pan fixing bolts and nuts to 10 Nm (87 inch lbs.).
3. Axle housing assembly [7]
- Tighten fixing bolts to 82 Nm (61 ft. lbs.).
- Tighten fixing bolts and nuts to 152 Nm (112 ft. lbs.).
4. Pitman arm and idler arm [6]
- Tighten idler arm fixing bolt to 44 Nm (33 ft. lbs.).
- Engage teeth of pitman arm and steering unit, and tighten bolt to 216 Nm (159 ft. lbs.).
5. Flywheel dust cover [5] 6. Suspension cross member [4]
- Tighten fixing bolts to 78 Nm (58 ft. lbs.).
7. Radiator under fan shroud [3]

8. Stone guard [2] 9. Dipstick [1]
- Fill oil to proper level.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation
Oil Pressure Gauge: Technical Service Bulletins Engine Oil Pressure Gauge/Lamp - Operation

ISSUE DATE January 7, 1993
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) ENGINE OIL PRESSURE
AFFECTED VEHICLES
1992-93 Trooper (UX) and 1993 Rodeo (UC) models equipped with 3.2L V6 engine.
SERVICE INFORMATION
Oil pressure gauge readings can vary greatly as oil temperature and engine speed change. A "low"
gauge reading at hot idle does not necessarily indicate a lubrication system problem.
This Service Bulletin describes oil pressure gauge and oil pressure warning light operation.
SERVICE PROCEDURE
Oil Pressure Gauge
Depending on oil temperature and engine RPM, the normal oil pressure gauge reading can range
from 8.5 psi at hot idle to more than 100 psi during cold acceleration (Figure 1).
If the engine oil pressure is below 8.5 psi, follow the appropriate Workshop Manual instructions for
diagnosis and repair procedures for the lubrication system and/or oil pressure gauge.
Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 1043
Oil Pressure Warning Light
If engine oil pressure falls to 2.8 psi or below during engine operation, the on pressure warning light
(Figure 2) will come on.
Refer to the appropriate Workshop Manual for lubrication system and/or oil pressure warning light
diagnosis and repair procedures.
Component Information > Technical Service Bulletins > Page 1044
Oil Pressure Gauge: Locations
Component ..........................................................................................................................................
................................................................. Photo No.
Dash Fuse Box - Left side of I/P, behind panel ...................................................................................

................................................................................ 63
Oil Pressure Sending Unit - Lower left front of engine, near oil filter
................................................................................................................................ 47
Oil Pressure Switch (2.6L) - Lower right rear of engine, above oil pan
.............................................................................................................................. 44
Oil Pressure Switch (3.2L) - Lower left front of engine, near oil filter
............................................................................................................................... 47
C128 (2-BLK) - Right side of engine compartment, next to fuse/relay box

........................................................................................................................ 39
C136 (12-BLU) - Left rear of engine compartment

............................................................................................................................................................
22
C173 (1 -GRY) - Lower left front of engine, near oil filter

................................................................................................................................................. 47
C196 (1-CLR) - Lower right side of engine compartment, near oil pan
.............................................................................................................................. 43
C197 (1-0LR) - Lower right side of engine compartment, near oil pan
.............................................................................................................................. 43

................................................................................................................................................ 71

............................................................................................................................................... 71

....................................................................................................................................................... 76

...................................................................................................................................................... 76

...................................................................................................................................................... 76
C200 - Below left side of I/P, behind engine control module (E0M)
.................................................................................................................................. 70
Oil Pressure Gauge: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Oil Pressure Gauge: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Oil Pressure Warning System
Component Information > Testing and Inspection > Quick Check
Oil Pressure Gauge: Testing and Inspection Quick Check

Component Information > Testing and Inspection > Quick Check > Page 1070
Oil Pressure Gauge: Testing and Inspection Diagnosis By Symptom
Needle Does Not Move
Fig. 19 Oil Gauge Diagnosis: Needle Does Not Move
Refer to Fig. 19, for oil gauge diagnosis.
Gauge Reading Is Too Low

Fig. 20 Oil Gauge Diagnosis: Gauge Reading Is Too Low
Needle Overshoots Gauge

Fig. 21 Oil Gauge Diagnosis: Needle Overshoots Gauge

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation
Oil Pressure Warning Lamp/Indicator: Technical Service Bulletins Engine Oil Pressure
Gauge/Lamp - Operation
GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
Oil Pressure Gauge
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation >
Page 1077
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure:
.................................................................................................................................................. 392 -
550 kPa (56.9 - 80.4 psi) at 3000 rpm.
(Normal operating temperature of about 80°C (176°F).)

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 1082
Engine Oil Pressure: Testing and Inspection
1. Check for dirt, gasoline or water in the engine oil.
a. Change the oil if dirt, gasoline, or water are present. b. Check the viscosity of the oil. c. Change
the oil if the viscosity is outside the specified standard. d. Refer to the Engine Lubrication.
2. Check the engine oil level.
- The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level
dipstick.
- If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit. 4. Install an oil pressure gage. 5. Start the engine and allow the
engine to reach normal operating temperature about 80°C (176°F). 6. Measure the oil pressure. Oil
pressure should be: 392 - 550 kPa (56.9 - 80.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the
oil pressure gage. 9. Install the oil pressure unit.
10. Start the engine and check for leaks.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure
Regulator Valve > Component Information > Testing and Inspection
Oil Pressure Regulator Valve: Testing and Inspection
CAUTION: Make necessary correction or parts replacement if wear, damage or any other abnormal
conditions are found through inspection.
- Check to see that the relief valve slides freely.
- The oil pump must be replaced if the relief valve does not slide freely.
- Replace the spring and/or the oil pump assembly if the spring is damaged or badly worn.
Refer to Oil Pump. See: Service and Repair

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Isuzu does not specify a torque sequence for the upper/lower intake manifold.
Intake Manifold: Diagrams
INTAKE MANIFOLD/WATER TEMP HOUSING

Intake Manifold: Description and Operation
Intake Manifold
PURPOSE
Routes intake air from the common chamber to the intake ports on the cylinder head.
LOCATION
On top of the engine.
CONSTRUCTION
It is a sealed cast aluminum component.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Intake Manifold Service and Repair
Intake Manifold: Service and Repair Intake Manifold Service and Repair
disarming and arming procedures. 2. Relieve fuel system pressure as outlined under Precautions.
Remove air cleaner assembly from engine compartment. 5. Disconnect vacuum hose from
evaporation canister, then air vacuum hoses from throttle valve and common chamber. 6.
Disconnect electrical connectors from MAP sensor, EGR VSV, MAT sensor and ground cable. 7.
Disconnect spark plug wires from cylinder head covers, then three DIS module electrical
connectors. 8. Remove throttle body, then the EGR valve. 9. Remove common chamber, then
disconnect fuel supply and return hoses from fuel rail.
10. Disconnect electrical connectors from fuel injectors, then thermo sensor connector. 11.
Remove intake manifold. 12. Reverse procedure to install. 13. On models equipped with airbag
system, refer to Technician Safety Information for system disarming and arming procedures.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Intake Manifold Service and Repair > Page 1093
Intake Manifold: Service and Repair Common Chamber Service and Repair
disarming and arming procedures. 2. Relieve fuel system pressure as outlined under Precautions.
Remove air cleaner assembly, then disconnect accelerator cable from throttle body and cable
bracket. 5. Mark vacuum line positions on common chamber, then disconnect hoses from common
chamber. 6. Disconnect spark plug wires from valve covers, then three electrical connectors from
DIS module. 7. Remove DIS module and spark plug wires from engine as an assembly. 8. Remove
throttle body, then EGR valve assembly. 9. Remove common chamber from engine.
10. Reverse procedure to install. 11. On models equipped with airbag system, refer to Technician
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
> Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation

GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
Oil Pressure Gauge
> Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 1099
> Component Information > Technical Service Bulletins > Page 1100
Component ..........................................................................................................................................
................................................................. Photo No.

................................................................................ 63
................................................................................................................................ 47
.............................................................................................................................. 44
............................................................................................................................... 47

........................................................................................................................ 39

............................................................................................................................................................
22

................................................................................................................................................. 47
.............................................................................................................................. 43
.............................................................................................................................. 43

................................................................................................................................................ 71

............................................................................................................................................... 71

....................................................................................................................................................... 76

...................................................................................................................................................... 76

...................................................................................................................................................... 76
.................................................................................................................................. 70
> Component Information > Diagrams > Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
> Component Information > Diagrams > Diagram Information and Instructions > Page 1103

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


> Component Information > Testing and Inspection > Quick Check

> Component Information > Testing and Inspection > Quick Check > Page 1126



Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning
Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation
GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
Oil Pressure Gauge
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning
Lamp/Indicator > Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation >
Page 1133
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Camshaft Oil Seal >
Component Information > Technical Service Bulletins > Recalls for Camshaft Oil Seal: > SB9401002 > Jul > 94 > Campaign
- Oil Leak From Camshaft End Plug
Technical Service Bulletin # SB9401002 Date: 940701
Campaign - Oil Leak From Camshaft End Plug
ISSUE DATE JULY 1994
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) CAMSHAFT END PLUG RETAINING PLATE CAMPAIGN
BULLETIN
CAMPAIGN IDENTIFICATION NUMBER
Number 94V-094 has been assigned to this campaign. This number will appear on all
communications and documentation of any nature dealing with the campaign.
SERVICE INFORMATION
Condition: Certain 1992-94 Trooper models with 3.2L 6VD1 engines (SOHC and DOHC versions)
and 1993-94 Rodeo models with 3.2L 6VD1 SOHC engines, may expenence dislodging of the
camshaft end plug(s) from the cylinder heads causing rapid oil loss. Continued operation of the
engine could result in engine damage, and in the worst case, an engine compartment fire from oil
spilling on the exhaust system.
AFFECTED VEHICLES
Possible Cause: Analysis indicates that this condition is most likely to occur in cold weather climate
and is attributable to the constant expansion and contraction of the cylinder head metal, which
causes the camshaft end plug(s) to become dislodged from the cylinder head.
Correction: To correct this condition, dealers will install a camshaft end plug retaining plate kit on all
affected vehicles. When installed, as described in this Campaign Bulletin, these parts will provide
the necessary support to keep the camshaft end plugs from dislodging and thus prevent any rapid
oil loss, potential engine damage, and fluid ignition.
DEALER RESPONSIBILITY
Isuzu Dealers are required to service all eligible vehicles at no charge to the owner, regardless of
mileage, age of vehicle, or ownership.
Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a

dealership for service, the dealer must take the necessary steps to ensure that this campaign
correction has been made before selling or releasing the vehicle.
Each Isuzu Dealer will be supplied a copy of the AIMI Campaign Report (AWS 123-1A) listing
affected vehicles assigned to that dealership. The report contains VIN and detailed owner
information obtained from state motor vehicle registration records. The use of such motor vehicle
registration data for any other purpose is a violation of law in several states. Accordingly, dealers
are urged to limit the use of this listing to the follow-up necessary to complete this campaign. If
none of the affected vehicles are assigned to a dealership, no campaign report will be sent.
OWNER NOTIFICATION
American Isuzu Motors Inc. will notify owners of affected vehicles already retailed by letter (see
enclosed copy). Dealers should follow up with vehicle
- Oil Leak From Camshaft End Plug > Page 1143
owners by sending a Campaign Reminder Notice (AIMI SVCF-1052) to all vehicle owners listed in
the AIMI Campaign Report AWS 123-1A. These postcards can be obtained from any regional
office.
PARTS INFORMATION
The parts listed have been shipped automatically to each dealer. The quantity of parts shipped is
dependent upon the dealer's sales volume of affected vehicles. These parts are also available from
American Isuzu Parts Distribution Network (AIPDN).
Use the new labor operations as shown.
Use Trouble Code 07 for all campaign operations. Labor time includes 0.1 administration
allowance.
Service Procedure
3.2L 6VD1-V SOHC Engine (1992-94 Trooper and 1993-1994 Rodeo)
^ Right-Hand - Rear
1. Remove the two cylinder head cover bolts (6 mm) (Figure 1).
2. Position the retaining plate over the camshaft end plug and secure the plate by reinstalling the
two cylinder head cover bolts. Tighten the two bolts to 65 in.-lb.
^ Left-Hand - Rear
1. Remove the air cleaner cover.
CAUTION:
The Exhaust Gas Recirculation (EGR) pipe generates high surface temperatures that can cause
severe burns. Make certain that the EGR pipe is cool to the touch when working in its vicinity.
2. Thread the two kit bolts (8 mm) into the rear of the cylinder head (Figure 1).
3. Position the retaining plate over the camshaft end plug and secure the plate by tightening the
two kit bolts to 191 in.-lb.
4. Reinstall the air cleaner cover.
5. Affix the Recall Campaign Label adjacent to the manufacturer's identification label located inside
the driver's door. Using a ball-point pen, fill in the label with Campaign Number 94V-094, the Isuzu
dealer code, and the repair date.
3.2L 6VD1-W DOHC Engine (1992-1994 Trooper Only)
^ Right-Hand - Rear
1. Remove the right-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the
ground wire washer.
2. Position the retaining plate over the camshaft end plugs and secure the plate using the ground
wire eyelet/bolt and kit bolt (6 mm). Tighten the two bolts to 70 in. lb.
^ Right-Hand - Front
1. Disconnect the negative battery harness clip (at the fuel line bracket.)
2. Remove the fuel line bracket bolt for better access to the cylinder head cover bolts.
4. Position the retaining plate over the camshaft end plugs and secure the plate by reinstalling the
5. Reinstall the fuel line bracket bolt and reconnect the negative battery harness clip.
^ Left-Hand - Front

2. Remove the two cylinder head cover bolts (6mm) (Figure 2).
^ Left-Hand - Rear
CAUTION:
1. Remove the left-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the ground
wire washer.
wire eyelet (bolt and kit bolt (6 mm). Tighten the two bolts to 70 in.lb.
dealer Code and the repair date.
Owner Letter
July 1994
Dear Isuzu Rodeo or Trooper Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act. Isuzu Motors Limited has determined that a defect which relates to motor
vehicle safety exists in all 1992-1993 and certain 1994 Isuzu Rodeo and Trooper vehicles with the
3.2 liter engine.
WHAT IS THE DEFECT?
These vehicles may exhibit a condition in which the camshaft seal end plug may become dislodged
from the cylinder head due to constant expansion and contraction of the cylinder head in cold
weather climates causing rapid oil loss. Continued operation of the engine could result in engine
damage, and in the worst case, an engine compartment fire from oil spilling on the exhaust system.
WHAT WE WILL DO?
To correct this condition, your dealer will install a camshaft plug retaining plate. This service will be
performed for you at no charge.
WHAT YOU SHOULD DO?
Please contact your local Isuzu dealer as soon as possible to arrange a service date. Instructions
for making this correction have been sent to your dealer and parts are available. Please ask your
dealer if you wish to know how much time will be needed to schedule and process your vehicle.
Presentation of this letter to your dealer will assist in making the necessary correction in the
shortest possible time. Please have your dealer refer to Campaign Bulletin SB94-O1-0o2. If you
have sold or traded your vehicle, please let us know by completing the postage paid reply card and
returning it to us.
Your Isuzu dealer is best equipped to obtain parts and provide service to ensure that your vehicle
is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the
agreed serviced date, and they do not remedy this condition on that date or within five (5) days, we
recommend you contact the appropriate Isuzu Regional office listed in the back of the Owner's
Manual or the National Customer Relations Office, American Isuzu Motors Inc., P.O. Box 2480,
City of Industry, CA 91746-0480, or call 1-800-255-6727. After contacting your dealer or Regional
Office or National Office, if you are still not satisfied that we have done our best to remedy this
condition without charge and within a reasonable time, you may wish to write the Administrator,
National Highway Traffic Safety Administration, 400 Seventh Street S.W., Washington, D.C. 20590;
or call 1-800-424-9393 (Washington D.C. residents can call 366-0123).
We are sorry to cause you this inconvenience; however, in the interest of your safety, it is very
important that your vehicle be returned to your Isuzu dealer as soon as possible for repair.
IMPORTANT:
If you have sold or traded your Isuzu vehicle, please enter the owners name and address, if known,
on the enclosed "Change of information" postcard and drop it in the mail. Postage has already
been paid. We will contact the new owner.
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Oil Seal: > SB9401002
> Jul > 94 > Campaign - Oil Leak From Camshaft End Plug
Technical Service Bulletin # SB9401002 Date: 940701
Campaign - Oil Leak From Camshaft End Plug
GROUP ENGINE
TROOPER (UX) AND RODEO (UC) CAMSHAFT END PLUG RETAINING PLATE CAMPAIGN
BULLETIN
CAMPAIGN IDENTIFICATION NUMBER
Number 94V-094 has been assigned to this campaign. This number will appear on all
communications and documentation of any nature dealing with the campaign.
SERVICE INFORMATION
Condition: Certain 1992-94 Trooper models with 3.2L 6VD1 engines (SOHC and DOHC versions)
and 1993-94 Rodeo models with 3.2L 6VD1 SOHC engines, may expenence dislodging of the
camshaft end plug(s) from the cylinder heads causing rapid oil loss. Continued operation of the
engine could result in engine damage, and in the worst case, an engine compartment fire from oil
spilling on the exhaust system.
AFFECTED VEHICLES
Possible Cause: Analysis indicates that this condition is most likely to occur in cold weather climate
and is attributable to the constant expansion and contraction of the cylinder head metal, which
causes the camshaft end plug(s) to become dislodged from the cylinder head.
Correction: To correct this condition, dealers will install a camshaft end plug retaining plate kit on all
affected vehicles. When installed, as described in this Campaign Bulletin, these parts will provide
the necessary support to keep the camshaft end plugs from dislodging and thus prevent any rapid
oil loss, potential engine damage, and fluid ignition.
DEALER RESPONSIBILITY
Isuzu Dealers are required to service all eligible vehicles at no charge to the owner, regardless of
mileage, age of vehicle, or ownership.
Whenever a vehicle subject to this campaign is in a dealer's vehicle inventory, or arrives at a

dealership for service, the dealer must take the necessary steps to ensure that this campaign
correction has been made before selling or releasing the vehicle.
Each Isuzu Dealer will be supplied a copy of the AIMI Campaign Report (AWS 123-1A) listing
affected vehicles assigned to that dealership. The report contains VIN and detailed owner
information obtained from state motor vehicle registration records. The use of such motor vehicle
registration data for any other purpose is a violation of law in several states. Accordingly, dealers
are urged to limit the use of this listing to the follow-up necessary to complete this campaign. If
none of the affected vehicles are assigned to a dealership, no campaign report will be sent.
OWNER NOTIFICATION
American Isuzu Motors Inc. will notify owners of affected vehicles already retailed by letter (see
enclosed copy). Dealers should follow up with vehicle
> Jul > 94 > Campaign - Oil Leak From Camshaft End Plug > Page 1152
owners by sending a Campaign Reminder Notice (AIMI SVCF-1052) to all vehicle owners listed in
the AIMI Campaign Report AWS 123-1A. These postcards can be obtained from any regional
office.
PARTS INFORMATION
The parts listed have been shipped automatically to each dealer. The quantity of parts shipped is
dependent upon the dealer's sales volume of affected vehicles. These parts are also available from
American Isuzu Parts Distribution Network (AIPDN).
Use the new labor operations as shown.
Use Trouble Code 07 for all campaign operations. Labor time includes 0.1 administration
allowance.
Service Procedure
3.2L 6VD1-V SOHC Engine (1992-94 Trooper and 1993-1994 Rodeo)
^ Right-Hand - Rear
2. Position the retaining plate over the camshaft end plug and secure the plate by reinstalling the
^ Left-Hand - Rear
CAUTION:
2. Thread the two kit bolts (8 mm) into the rear of the cylinder head (Figure 1).
3. Position the retaining plate over the camshaft end plug and secure the plate by tightening the
two kit bolts to 191 in.-lb.
dealer code, and the repair date.
3.2L 6VD1-W DOHC Engine (1992-1994 Trooper Only)
^ Right-Hand - Rear
1. Remove the right-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the
ground wire washer.
wire eyelet/bolt and kit bolt (6 mm). Tighten the two bolts to 70 in. lb.
^ Right-Hand - Front
1. Disconnect the negative battery harness clip (at the fuel line bracket.)
2. Remove the fuel line bracket bolt for better access to the cylinder head cover bolts.
5. Reinstall the fuel line bracket bolt and reconnect the negative battery harness clip.
^ Left-Hand - Front

2. Remove the two cylinder head cover bolts (6mm) (Figure 2).
^ Left-Hand - Rear
CAUTION:
1. Remove the left-hand-side ground wire bolt (6 mm)/washer/eyelet (Figure 2). Discard the ground
wire washer.
wire eyelet (bolt and kit bolt (6 mm). Tighten the two bolts to 70 in.lb.
dealer Code and the repair date.
Owner Letter
July 1994
Dear Isuzu Rodeo or Trooper Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act. Isuzu Motors Limited has determined that a defect which relates to motor
vehicle safety exists in all 1992-1993 and certain 1994 Isuzu Rodeo and Trooper vehicles with the
3.2 liter engine.
WHAT IS THE DEFECT?
These vehicles may exhibit a condition in which the camshaft seal end plug may become dislodged
from the cylinder head due to constant expansion and contraction of the cylinder head in cold
weather climates causing rapid oil loss. Continued operation of the engine could result in engine
damage, and in the worst case, an engine compartment fire from oil spilling on the exhaust system.
WHAT WE WILL DO?
To correct this condition, your dealer will install a camshaft plug retaining plate. This service will be
performed for you at no charge.
WHAT YOU SHOULD DO?
Please contact your local Isuzu dealer as soon as possible to arrange a service date. Instructions
for making this correction have been sent to your dealer and parts are available. Please ask your
dealer if you wish to know how much time will be needed to schedule and process your vehicle.
Presentation of this letter to your dealer will assist in making the necessary correction in the
shortest possible time. Please have your dealer refer to Campaign Bulletin SB94-O1-0o2. If you
have sold or traded your vehicle, please let us know by completing the postage paid reply card and
returning it to us.
Your Isuzu dealer is best equipped to obtain parts and provide service to ensure that your vehicle
is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the
agreed serviced date, and they do not remedy this condition on that date or within five (5) days, we
recommend you contact the appropriate Isuzu Regional office listed in the back of the Owner's
Manual or the National Customer Relations Office, American Isuzu Motors Inc., P.O. Box 2480,
City of Industry, CA 91746-0480, or call 1-800-255-6727. After contacting your dealer or Regional
Office or National Office, if you are still not satisfied that we have done our best to remedy this
condition without charge and within a reasonable time, you may wish to write the Administrator,
National Highway Traffic Safety Administration, 400 Seventh Street S.W., Washington, D.C. 20590;
or call 1-800-424-9393 (Washington D.C. residents can call 366-0123).
We are sorry to cause you this inconvenience; however, in the interest of your safety, it is very
important that your vehicle be returned to your Isuzu dealer as soon as possible for repair.
IMPORTANT:
If you have sold or traded your Isuzu vehicle, please enter the owners name and address, if known,
on the enclosed "Change of information" postcard and drop it in the mail. Postage has already
been paid. We will contact the new owner.
Camshaft Oil Seal: Service and Repair
Oil Seal Installation
Apply engine oil to the camshaft oil seal lip and install new camshaft oil seal with Camshaft oil seal
installer J-39203.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
REMOVAL
1. Transmission assembly. Refer to transmission and drivetrain. 2. Flywheel. 3. Rear oil seal.
- Remove using a seal puller.
NOTE: Take care not to damage the crankshaft or oil seal retainer when removing oil seal.
INSTALLATION
1. Rear oil seal [3]
- Apply engine oil to the oil seal lip, and install oil seal using installer: J-39201.
2. Flywheel [2]
- Clean tapped holes in the crankshaft.
- Remove oil on crankshaft and flywheel mounting surface.
NOTE:
- Do not reuse the bolts.
- Do not apply oil or thread lock to the bolts.
- Tighten bolts to 54 Nm (40 ft. lbs.).
3. Transmission [1]
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 1160
CAUTION: When assembling the engine and transmission, confirm that dowels have been
mounted in the specified positions at the engine side. Besides, take care that dowel positions are
different between the manual transmission and the automatic transmission. If assembled in the
condition that dowels have not been mounted in the specified positions, it results in the
transmission broken.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Timing Cover Oil Seal
<--> [Front Crankshaft Seal] > Component Information > Service and Repair
Timing Cover Oil Seal: Service and Repair
disarming and arming procedures. 2. Disconnect battery ground cable. 3. Remove timing belt. See:
Timing Components/Timing Belt Then remove crankshaft pulley hub. 4. Using care not to damage
crankshaft or seal housing, pry out seal using a suitable tool. 5. Reverse procedure to install, noting
the following:
a. Lubricate sealing lips of new seal before installing. b. Use seal driver tool No. J-35269, or
equivalent to install new seal. c. Tighten bolts to specification.
disarming and arming procedures.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component
Information > Testing and Inspection
Timing Belt: Testing and Inspection
TIMING BELT INSPECTION
Visual check
1. The belt must be replaced if cracks or lacerations are found in the side and rear faces.
2. replacement is necessary when abnormal wear is found in the side face.
3. Replacement is necessary when belt fabric is found to be cracked or disintegrated.
4. Replacement is also necessary when cogs are found to have abnormal wear.
5. Take measurements at 3 - 5 points around the circumference of the belt The belt must be
replaced even if a single measurement is beyond the limit.
Limit of rubber hardness - 90 (HS)

Information > Testing and Inspection > Page 1168
Timing Belt: Service and Repair
REMOVAL STEPS
Preparation: Battery ground cable
- Remove from radiator.
- Remove four nuts, then the cooling fan assembly.
4. Air Conditioning compressor drive belt
6. Power stering pump drive belt

- Using special tool J-8614-O1, hold crankshaft pulley.
- Remove center bolt, then the pulley.
10. Oil cooler hose
- Remove two cooler hose bracket fixing bolts on the timing cover.
12. Pusher
CAUTION: -
The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.
INSTALLATION STEPS
13. Timing belt
CAUTIONS: -
Do not bend or twist the belt, otherwise its core could be damaged. The belt should not be bent at a
radius less than 3Omm.
- Do not allow oil or other chemical substances to come in contact with the belt. They will shorten
the belt life.
- Do not attempt to pry or stretch the belt with a screwdriver or any other tool during installation.
- Store timing belt in a cool and dark place. Never expose the belt to direct sunlight or heat.
1) Align groove of crankshaft timing pulley with mark on oil pump.

2) Align the marks on the camshaft timing pulleys with the corresponding dots on the front plate.
NOTE: -
When timing marks are aligned, no pistons will be on T.D.C.
3) Install timing belt. Align the dotted alignment mark on the timing belt with the mark on the
crankshaft gear.
NOTE: -
For correct belt installation, the letters the belt must be able to be read as viewed from the front of
the vehicle. It is recommended for easy installation that the belt be secured with double clips after it
is installed to each pulley.
4) Align the alignment mark (white line) on the timing belt with the alignment mark on the RH bank
camshaft timing pulley (on the left side as
viewed from the front of the vehicle Secure the belt with a double clip.
5) Turn the crankshaft counterclockwise to remove the belt slack between the crankshaft timing
pulley and the RH bank camshaft timing pulley.
6) Install the belt on the water pump pulley.
7) Install the belt on the idler pulley.
8) Align the alignment mark (white line) on the timing belt with the alignment mark on the LH bank
camshaft timing pulley. If the belt is difficult
to install turn the camshaft pulley slightly counterclockwise.
9) Install crankshaft pulley temporarily and tighten center bolt by hand (do not use a wrench). Turn
the crankshaft pulley clockwise to give some
slack between the crankshaft timing pulley and the RH bank camshaft timing pulley.
10) Install the pusher while pushing the tension pulley to the belt.
11) Pull out the pin from the pusher.
NOTE: -
When reusing the pusher, press the pusher to retract the rod and insert a pin (1.4 mm piano wire).
12) Remove double clips from pulleys. Turn the crankshaft pulley clockwise by two turns. Measure
the rod protrusion to ensure it is within the
standard.
Standard 4-6 mm (0.16-0.24 in)
13) If out of standard, remove pusher, loosen adjusting bolt, and readjust. (Repeat from step 11).
Tighten adjusting bolt to the specified torque.
12. Pusher
- Tighten bolt to the specified torque.
- Remove crankshaft pulley that was installed in step 9.
- Tighten bolts to the specified torque.
10. Oil cooler hose
- Tighten oil cooler hose bracket bolts to the specified torque.
- Using special tool J-8614-01, hold the crankshaft pulley.
- Tighten center bolt to the specified torque.
8. Crankshaft pulley; P/S belt

6. Power steering tension pulley
4. Air Conditioning drive belt
- Tighten nuts to the specified torque.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner >
Component Information > Specifications > Torque Specifications
Timing Belt Tensioner: Specifications
Tensioner Adjusting Bolt 31 ft.lb
Tension Pusher Bolts 14 ft.lb

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner >
Component Information > Specifications > Torque Specifications > Page 1178
Timing Belt Tensioner: Specifications
Tension Pusher Rod Protrusion Standard 0.16 - 0.24 in

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Timing Cover: Specifications
Timing Belt Cover Bolts 12 ft.lb

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Locations
Component Locations

Pressure > Fuel Pressure Test Port > Component Information > Locations > Page 1187
PURPOSE
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Specifications

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Specifications > Page 1191
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 1195
speed.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Cleaner Filter <--> [Air Filter Element] > Component Information > Description and Operation
Air Filter
PURPOSE
OPERATION
chamber.
CONSTRUCTION

Cleaner Housing > Air Cleaner Filter <--> [Air Filter Element] > Component Information > Description and Operation > Page
1200
Cleaner Housing > Air Cleaner Filter <--> [Air Filter Element] > Component Information > Description and Operation > Page
1201
REMOVAL

CLEANING
INSTALLATION
3. Air cleaner hose

Filter > Fuel Pressure Release > System Information > Service Precautions
following items:
lubricated.)
Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1206
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Cable > Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark
Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: >
SB97-01-L003 > Jun > 97 > Spark Plug Tube - Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: >
SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Cable > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: >
SB97-01-L003 > Jun > 97 > Spark Plug Tube - Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
Cable > Component Information > Technical Service Bulletins > Page 1236
No.1 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.2 .....................................................................................................................................................
................................................ 5.7 - 13.1 K Ohms
No.3 .....................................................................................................................................................
................................................ 6.2 - 14.4 K Ohms
No.4 .....................................................................................................................................................
................................................ 5.8 - 13.3 K Ohms
No.5 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.6 .....................................................................................................................................................
................................................ 6.9 - 16.0 K Ohms
Ignition Wire
PURPOSE
CONSTRUCTION
Cable # ................................................................................................................................................
.............................................................. x 1000 ohms
1 ...........................................................................................................................................................
................................................................... 6.4 - 14.9 2 ......................................................................
........................................................................................................................................................ 5.7
- 13.1 3 ................................................................................................................................................
.............................................................................. 6.2 - 14.4 4 ...........................................................
..............................................................................................................................................................
..... 5.8 - 13.3 5 ....................................................................................................................................
.......................................................................................... 6.4 - 14.9 6 ...............................................
..............................................................................................................................................................
................. 6.9 - 16.0
Remove wires.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug
Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: >
SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure
GROUP: ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1258

SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1259
SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement
GROUP ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 1264
SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement > Page 1265
(2.56 in. +/- .02 in).

Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 >
Apr > 96 > Spark Plug Tube - Replacement Procedure
GROUP: ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1271

Apr > 96 > Spark Plug Tube - Replacement Procedure > Page 1272
Plug > Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 >
Aug > 95 > Spark Plug Tube - Replacement
GROUP ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
Aug > 95 > Spark Plug Tube - Replacement > Page 1277
Aug > 95 > Spark Plug Tube - Replacement > Page 1278
(2.56 in. +/- .02 in).

Plug > Component Information > Specifications > Electrical Specifications

..................................................... 50 Mohms or more
Plug > Component Information > Specifications > Electrical Specifications > Page 1281
Spark plug gap ....................................................................................................................................

.................................. 0.040 - 0.043 in (1.0 - 1.1 mm)

......................................................... 13 ft lb (18 Nm)
Plug > Component Information > Specifications > Page 1282

PURPOSE
HEAT RANGE
plug to be hotter.
occur.
Plug > Component Information > Specifications > Page 1283
INSPECTION
RESISTANCE
50 M ohms
1.05 mm (0.040 in)
SOOTY SPARK PLUGS
Rich fuel mixture.
Lean fuel mixture.

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > System Diagnosis
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: >
SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

SB00-01-S009 > Sep > 00 > Engine Valve Train - Ticking Noise > Page 1295
Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 >
Sep > 00 > Engine Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Sep > 00 > Engine Valve Train - Ticking Noise > Page 1304
Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Clearance > System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1308
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
GROUP: ENGINE
NOTE:

AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION
Service Procedure

NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
Clearance > System Information > Technical Service Bulletins > Page 1318
Stem Diameter:
Intake ...................................................................................................................................................
...................................... 0.2346-0.2323 inches Exhaust .....................................................................
................................................................................................................. 0.2343-0.2323 inches

............................................................................... 45 Valve Clearance:
Intake ...................................................................................................................................................
.................................................................. [01] Exhaust ......................................................................
............................................................................................................................................ [01]

Clearance > System Information > Technical Service Bulletins > Page 1319

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Technical
Service Bulletins > Water Pump - Installation (Manual Revision)
Water Pump: Technical Service Bulletins Water Pump - Installation (Manual Revision)
GROUP: ENGINE
1992-97 TROOPER (UX) AND 1993-97 RODEO (UC) 3.2L V6 ENGINE WATER PUMP
ASSEMBLY INSTALLATION (Workshop Manual Revision)
AFFECTED VEHICLES
1992-97 Trooper (UX) models. 1993-97 Rodeo (UC) models equipped with 3.2L V6 engine.
SERVICE INFORMATION
The water pump installation procedure contained in Section 6B - Engine Cooling (1992-97 Trooper)
and in Section 6B1A - Engine Cooling (1993-97 Rodeo) of the listed Workshop Manuals, has been
revised.
Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1324
The water pump installation procedure has been revised to include a note to apply LOCTITE 262,
or equivalent, to the No. 3 water pump retaining bolt threads to prevent oil leakage.
Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1325
pages.
Service Bulletins > Page 1326
Water Pump: Service and Repair

disarming and arming procedures. 2. Disconnect battery ground cable, then insulate cable end with
electrical tape. 3. Drain engine coolant from radiator. 4. Remove timing belt. 5. Remove idler pulley,
then the water pump.
Fig. 69 Water Pump Tightening Sequence
a. Ensure all gasket material has been removed from engine block sealing surface. b. Torque water
pump retaining bolts in sequence shown, Fig. 69, to 13 ft. lbs. c. Tighten idler pulley retaining bolt
to specification.
7. Timing Belt
^ Install timing belt and adjust the belt tension. See: Timing Components/Timing Belt/Service and
Repair
^ connect radiator inlet hose and replenish coolant.
^ Connect battery ground cable.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Technical Service Bulletins > Engine Coolant - Propylene Glycol Acceptable for Use
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Acceptable for Use
ISSUE DATE
JANUARY 1996
GROUP MISCELLANEOUS
PROPYLENE GLYCOL - BASED ENGINE COOLANT (Supersedes SB94-14-005)
AFFECTED VEHICLES
All Isuzu passenger, sport utility, and light truck models.
SERVICE INFORMATION
Isuzu has determined that propylene glycol-based engine coolants, such as Safe Brands' Sierra
engine coolant, will perform adequately under most vehicle operating conditions. As a result,
propylene glycol-based engine coolants may be used in Isuzu vehicles.
A few important points to remember regarding propylene glycol-based engine coolants:
^ Freeze/boil point levels for propylene glycol are different than for ethylene glycol.
^ To accurately determine the freeze/boil protection level, it is imperative that the coolants not be
mixed.
^ Prior to adding propylene glycol engine coolant to the cooling system, all ethylene glycol coolant
must be removed.
^ When changing the coolant to propylene glycol, be certain to thoroughly flush the heater core and
block as well as the radiator.
Technical Service Bulletins > Engine Coolant - Propylene Glycol Acceptable for Use > Page 1332
Coolant: Technical Service Bulletins Coolant - Propylene Glycol Not Approved by Isuzu
GROUP MISCELLANEOUS
PROPYLENE GLYCOL-BASED ENGINE COOLANT WARNING
AFFECTED VEHICLES
All Isuzu passenger and light duty models.
SERVICE INFORMATION
Some new propylene glycol-based engine coolants, such as Safe Brands' Sierra engine coolant,
have recently been marketed in the automotive service industry as "environmentally safe"
alternatives to conventional ethylene glycol-based engine coolants.
Propylene glycol-based engine coolants are not approved by Isuzu for use in Isuzu vehicles.
Propylene glycol-based engine coolants do not meet Isuzu engine coolant specifications. Use of
propylene glycol-based engine coolants in Isuzu vehicles can cause the following:
^ Reduced heater and defroster performance.
^ Decreased boil protection and freeze protection.
^ Decreased cylinder head heat transfer.
^ Corrosion damage to cooling system metals (if mixed with ethylene glycol-based engine coolant).
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity, Quarts:
Manual Transmission ..........................................................................................................................

.................................................................... 9.7 Automatic Transmission ...........................................
............................................................................................................................................... 9.3
Specifications > Capacity Specifications > Page 1335
Coolant: Fluid Type Specifications
EC - Ethylene Glycol Coolant

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Service and Repair
Radiator Cooling Fan Motor: Service and Repair
1. Remove upper radiator hose, then loosen water pump drive belt.
Fig. 1 Lower Fan Shroud Retaining Clips
2. Remove radiator fan shroud by releasing two clips holding lower shroud to upper shroud, Fig. 1,
then remove four bolts holding upper shroud to
radiator and lift shroud out.
Fig. 2 Fan Clutch To Water Pump Nuts
3. Remove nuts holding fan clutch to water pump hub, then lift out fan and clutch assembly. .
Reverse procedure to install torque fan clutch to water pump flange nuts to 7.4 ft. lbs., Fig. 2.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
-18°C (0°F) ..........................................................................................................................................

.................................................................. 25K ohms -7°C (20°F) ......................................................
................................................................................................................................................... 13.5K
ohms 4°C (40°F) ..................................................................................................................................
.......................................................................... 7.5K ohms 20°C (68°F) ............................................
..............................................................................................................................................................
3.4K ohms 38°C (100°F) .....................................................................................................................
................................................................................... 1.8K ohms 70°C (160°F) .................................
..............................................................................................................................................................
........... 450 ohms 100°C (212°F) .........................................................................................................
............................................................................................... 185 ohms
> Engine Temperature Sensor > Component Information > Specifications > Page 1344
ECT Sensor

ECT Sensor
PURPOSE
OPERATION
CONSTRUCTION
266°F).
ECT Sensor
REMOVAL
INSTALLATION
torque
system.
> Temperature Sensor (Gauge) > Component Information > Locations

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core -
Coolant Leakage
Heater Core: All Technical Service Bulletins Heater Core - Coolant Leakage
GROUP: HEATING AND A/C
HEATER CORE AND CASING LEAKAGE (SUPERSEDES SB00-12-S001)
NOTE:
Shaded information reflects changes from previous service bulletin.
AFFECTED VEHICLES
^ 1997 and prior Rodeo (UC) models
^ All 1995 and prior Pickup (TF) - SIA built models
Condition: Coolant leakage may be present near the heater core area.
Possible Cause: Aluminum-type core may have eroded resulting in a leak
Correction: To correct this condition, install revised (copper) heater core and casing to replace the
existing (aluminum) heater core and casing.
SERVICE PROCEDURE
Refer to published procedure in the appropriate Workshop Manual.
PARTS INFORMATION
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core -
Coolant Leakage > Page 1359

Technical Service Bulletins > Customer Interest for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant
Leakage
Heater Core: Customer Interest Heater Core - Coolant Leakage
NOTE:
AFFECTED VEHICLES
SERVICE PROCEDURE
PARTS INFORMATION
Technical Service Bulletins > Customer Interest for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant
Leakage > Page 1365

Technical Service Bulletins > Page 1366
Heater Core: Service and Repair
HEATER UNIT / CORE Removal Procedure
disarming and arming procedures. 2. Disconnect battery ground cable, drain cooling system. 3. On
models with A/C, discharge and recover A/C system. 4. Remove instrument panel as outlined in
Dash Panel section. 5. On models with A/C, proceed as follows:
a. Remove evaporator to compressor and receiver tank flare nuts. b. Disconnect resistor
connectors. c. Remove three evaporator retaining nuts, then the evaporator assembly.
6. Disconnect heater hoses from heater core, then remove side ventilator duct. 7. Remove four
heater unit retaining nuts, then the heater unit assembly. 8. Remove defroster door rod and lever.
9. Remove plate and seal, then the heater core.
a. Torque evaporator to receiver tank nut to 10-20 ft. lbs. b. Torque evaporator to compressor nut
to 20-22 ft. lbs.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures
Temperature Gauge: Symptom Related Diagnostic Procedures
Fig. 3 Temperature Gauge Diagnosis: Needle Does Not Move
Refer to Fig. 3 for temperature gauge diagnosis.

Temperature Gauge > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page
1372
Fig. 4 Temperature Gauge Diagnosis: Gauge Reading Is Too Low
Refer to Fig. 4, for temperature gauge diagnosis.
Needle Goes Past 'H'

1373
Fig. 5 Temperature Gauge Diagnosis: Needle Goes Past "H"

1374
Temperature Gauge: Component Tests and General Diagnostics

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair
Radiator: Service and Repair
disarming and arming procedures. 2. Disconnect battery ground cable. 3. Drain engine coolant
from radiator.
Fig. 73 Radiator Replacement
4. Remove automatic transmission oil cooler lines, Fig. 73. 5. Remove radiator hoses. 6. Remove
lower cooling fan guide. 7. Remove reserve tank hose from filler neck. 8. Remove support bracket.
9. Remove radiator.
10. Reverse procedure to install. 11. On models equipped with airbag system, refer to Technician
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Specifications
Radiator Cap: Specifications
Radiator Cap Relief Pressure, Lbs. .....................................................................................................

............................................................................... 15
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
-18°C (0°F) ..........................................................................................................................................

.................................................................. 25K ohms -7°C (20°F) ......................................................
................................................................................................................................................... 13.5K
ohms 4°C (40°F) ..................................................................................................................................
.......................................................................... 7.5K ohms 20°C (68°F) ............................................
..............................................................................................................................................................
3.4K ohms 38°C (100°F) .....................................................................................................................
................................................................................... 1.8K ohms 70°C (160°F) .................................
..............................................................................................................................................................
........... 450 ohms 100°C (212°F) .........................................................................................................
............................................................................................... 185 ohms
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications >
Page 1386
ECT Sensor

Page 1387
ECT Sensor
PURPOSE
OPERATION
CONSTRUCTION
266°F).
Page 1388
ECT Sensor
Page 1389
REMOVAL
INSTALLATION
torque
system.
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations

Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Symptom Related Diagnostic Procedures

Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 1397



Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Thermostat: Specifications
Thermostat Opening Temperature ......................................................................................................

.......................................................................... 170°F
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Thermostat: Service and Repair
disarming and arming procedures. 2. Disconnect battery ground cable. 3. Drain coolant from
radiator. 4. Disconnect thermoswitch electrical connector, then the upper radiator hose from
thermostat housing. 5. Remove thermostat housing and thermostat from engine assembly. Note
installation position of jiggle valve before removing thermostat. 6. Reverse procedure to install,
noting the following:
a. Ensure thermostat housing sealing surfaces are free of old gasket material. b. Install thermostat
with jiggle valve positioned at 12 o'clock. c. Tighten thermostat housing retaining bolts to
specification.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Technical Service Bulletins > Water Pump - Installation (Manual Revision)
Water Pump: Technical Service Bulletins Water Pump - Installation (Manual Revision)
GROUP: ENGINE
1992-97 TROOPER (UX) AND 1993-97 RODEO (UC) 3.2L V6 ENGINE WATER PUMP
ASSEMBLY INSTALLATION (Workshop Manual Revision)
AFFECTED VEHICLES
1992-97 Trooper (UX) models. 1993-97 Rodeo (UC) models equipped with 3.2L V6 engine.
SERVICE INFORMATION
The water pump installation procedure contained in Section 6B - Engine Cooling (1992-97 Trooper)
and in Section 6B1A - Engine Cooling (1993-97 Rodeo) of the listed Workshop Manuals, has been
revised.
Technical Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1408
The water pump installation procedure has been revised to include a note to apply LOCTITE 262,
or equivalent, to the No. 3 water pump retaining bolt threads to prevent oil leakage.
Technical Service Bulletins > Water Pump - Installation (Manual Revision) > Page 1409
pages.
Water Pump: Service and Repair

electrical tape. 3. Drain engine coolant from radiator. 4. Remove timing belt. 5. Remove idler pulley,
then the water pump.
Fig. 69 Water Pump Tightening Sequence
a. Ensure all gasket material has been removed from engine block sealing surface. b. Torque water
pump retaining bolts in sequence shown, Fig. 69, to 13 ft. lbs. c. Tighten idler pulley retaining bolt
to specification.
7. Timing Belt
^ Install timing belt and adjust the belt tension. See: Engine/Timing Components/Timing
Belt/Service and Repair
^ connect radiator inlet hose and replenish coolant.
^ Connect battery ground cable.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Locations
Catalytic Converter: Locations
LOCATION
Two (2) catalytic converters are used downstream of the exhaust manifold to reduce oxides of
nitrogen (NOx) and oxidize hydrocarbons (HC) and carbon monoxide (CO).
> Description and Operation > California
Catalytic Converter: Description and Operation California
PURPOSE
Reduces exhaust emissions.
OPERATION and CONSTRUCTION
The rear three-way converter contains the catalyst elements platinum, rhodium and palladium
which promote oxidation and reduction reactions at high temperatures. Emissions are converted
into carbon dioxide, water vapor and nitrogen.
An oxidizing catalyst, Pre Converter, mounted directly in the exhaust manifold, is also used to
oxidize excess hydrocarbons that occur in the exhaust when the engine is cold.
> Description and Operation > California > Page 1417
Catalytic Converter: Description and Operation Federal
Three-Way Catalytic Converter
PURPOSE
To reduce exhaust emissions of NOx, HC, and CO.
OPERATION
A three-way catalytic converter is used downstream of the exhaust manifold to reduce oxides of
nitrogen (NOx) and oxidize hydrocarbons (HC) and carbon monoxide (CO). Emissions are
converted into carbon dioxide, water vapor and nitrogen.
CONSTRUCTION
The converter contains the catalyst elements platinum, rhodium and palladium which promote
oxidation and reduction reactions at high temperatures.
> Description and Operation > Page 1418
Catalytic Converter: Testing and Inspection
CATALYTIC CONVERTER INSPECTION
1. Visually inspect exterior of converter. If severe damage is noted, such a dented, crushed or
rusted out shell, replace converter.
2. Whenever converter is removed from vehicle, check ceramic element through exhaust inlet and
outlet. If element is clogged, melted or otherwise damaged, replace converter.
Exhaust System Back Pressure Check (Using Oxygen Sensor Mounting Hole)
RESTRICTED EXHAUST SYSTEM CHECK AT OXYGEN SENSOR
1. Remove oxygen sensor.
2. In place of the sensor, install a Boroughs exhaust backpressure tester (BT8515 or BT8603) or
equivalent
3. With engine idling at normal operating temperature, the gauge reading should not exceed 8.6
kPa (1.25 psi).
4. Increase engine speed to 2000 rpm. Gauge reading should not exceed 20.7 kPa (3 psi).
5. If backpressure at either speed exceeds specification, a restricted exhaust system is indicated.
6. Inspect exhaust system for a collapsed pipe, heat distress or possible internal muffler failure.
7. If no obvious reasons for excessive exhaust system backpressure are found, suspect a
restricted catalytic converter.
8. After completing test, coat threads of oxygen sensor with anti-seize compound prior to
reinstallation.
> Service and Repair > Federal
Catalytic Converter: Service and Repair Federal
Exhaust System
1. Raise and support vehicle in a safe manner.
2. Check that converter is cool enough to work with.
3. Remove bolts at front and rear of converter, remove converter and gaskets.
4. When reinstalling original or new converter, use new gaskets at front and rear pipe connections.
5. When installing new gaskets, ensure that the "U" marks on the gaskets are oriented at the top.
6. Install bolts and tighten to complete installation.

> Service and Repair > Federal > Page 1421
Catalytic Converter: Service and Repair California
TWC
Exhaust System

> Service and Repair > Federal > Page 1422
Pre-Cat
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair
Exhaust Manifold: Service and Repair
suitable electrical tape. 3. If removing left manifold, remove EGR pipe. 4. Disconnect front exhaust
pipe from manifold. 5. Remove five heat protector retaining bolts, then the heat protector. 6.
Remove seven exhaust manifold retaining nuts, then the manifold. 7. Reverse procedure to install.
Isuzu Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > SB95-03-L001 > Nov > 95 >
Exhaust System - Rattling Noise
Heat Shield: All Technical Service Bulletins Exhaust System - Rattling Noise
GROUP EMISSIONS
RODEO (UC) AND PICKUP (TF) 4ZE1 CATALYTIC CONVERTER RATTLING NOISE
AFFECTED VEHICLES
1993-95 Rodeo (UC) and 1994-95 Pickup (TF) models equipped with 4ZE1 engine.
SERVICE INFORMATION
On some affected vehicles, a rattling noise may be heard coming from the catalytic converter. This
rattling results from cracking of the catalytic converter heat shield due to metal fatigue.
To correct the problem, install a new heat shield (Part No. 8-97130-025-0) using the procedure
described in this Service Bulletin. The new heat shield has been reinforced to provide improved
fatigue resistance.
REMOVAL
1. Heat Shield
^ Remove four holding nuts.
^ Remove heat shield from bracket.
INSTALLATION
1. Heat Shield
^ Install new heat shield (Figure 1) onto bracket.
^ Tighten four holding nuts to 18 NM (13 ft. lbs.)
PARTS INFORMATION
Part No. Description Quantity

Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > SB95-03-L001 > Nov > 95 >
Exhaust System - Rattling Noise > Page 1434
8-97130-025-0 Protector; Heat 1
(heat shield)
Use the existing labor operation as shown.

Information > Technical Service Bulletins > Customer Interest for Heat Shield: > SB95-03-L001 > Nov > 95 > Exhaust
System - Rattling Noise
Heat Shield: Customer Interest Exhaust System - Rattling Noise
GROUP EMISSIONS
RODEO (UC) AND PICKUP (TF) 4ZE1 CATALYTIC CONVERTER RATTLING NOISE
AFFECTED VEHICLES
1993-95 Rodeo (UC) and 1994-95 Pickup (TF) models equipped with 4ZE1 engine.
SERVICE INFORMATION
On some affected vehicles, a rattling noise may be heard coming from the catalytic converter. This
rattling results from cracking of the catalytic converter heat shield due to metal fatigue.
To correct the problem, install a new heat shield (Part No. 8-97130-025-0) using the procedure
described in this Service Bulletin. The new heat shield has been reinforced to provide improved
fatigue resistance.
REMOVAL
1. Heat Shield
^ Remove four holding nuts.
^ Remove heat shield from bracket.
INSTALLATION
1. Heat Shield
^ Install new heat shield (Figure 1) onto bracket.
^ Tighten four holding nuts to 18 NM (13 ft. lbs.)
PARTS INFORMATION

Information > Technical Service Bulletins > Customer Interest for Heat Shield: > SB95-03-L001 > Nov > 95 > Exhaust
System - Rattling Noise > Page 1440
8-97130-025-0 Protector; Heat 1
(heat shield)

Isuzu Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications

terminal.
Modules - Computers and Control Systems > Engine Control Module > Component Information > Specifications > Page
1447
ECM

1448
Inputs And Outputs
PURPOSE
OPERATION
1449
IMPORTANT NOTE!
ECM TESTING
1450
ECM
components.
REMOVAL
INSTALLATION
1. ECM

Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Fuse Panel

Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 1454
PURPOSE
OPERATION
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuse Panel

Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1459
Fuel Pump Circuit
PURPOSE
LOCATION

OPERATION
fuel pump.
Fuel Pump Circuit

Circuit Description
Test Description
Diagnostic Aids
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Fuse Panel

Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 1465
PURPOSE
OPERATION
Modules - Ignition System > Ignition Control Module > Component Information > Locations
Coil Pack

Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 1470
Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 1471
REFIT
Isuzu Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
87 in lb (10 Nm)
Page 1477

Page 1478
PURPOSE
engine speed.
Page 1479
REMOVE
Protection Shield
REFIT
87 in lb (10 Nm)
46 ft lb (63 Nm)
27 ft lb (37 Nm)

Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
-18°C (0°F) ..........................................................................................................................................

.................................................................. 25K ohms -7°C (20°F) ......................................................
................................................................................................................................................... 13.5K
ohms 4°C (40°F) ..................................................................................................................................
.......................................................................... 7.5K ohms 20°C (68°F) ............................................
..............................................................................................................................................................
3.4K ohms 38°C (100°F) .....................................................................................................................
................................................................................... 1.8K ohms 70°C (160°F) .................................
..............................................................................................................................................................
........... 450 ohms 100°C (212°F) .........................................................................................................
............................................................................................... 185 ohms
Page 1483
ECT Sensor

Page 1484
ECT Sensor
PURPOSE
OPERATION
CONSTRUCTION
266°F).
Page 1485
ECT Sensor
Page 1486
REMOVAL
INSTALLATION
torque
system.
Temperature ........................................................................................................................................
............................................................... Resistance
20°F (-7°C) ..........................................................................................................................................

............................................................... 13.5K ohms 68°F (20°C) .....................................................
..................................................................................................................................................... 3.4K
ohms 100°F (38°C) ..............................................................................................................................
.......................................................................... 1.8K ohms

MAT Sensor
PURPOSE
OPERATION
CONSTRUCTION
REMOVAL
INSTALLATION
torque.
- Wiring connector
Below 305 / 1000..................................................................................................................................

........................................................3.8 - 5.5V 305-610 / 1000-2000....................................................
.................................................................................................................................3.6 - 5.3V
914-1219 / 3000-4000..........................................................................................................................
.........................................................3.3 - 5.0V 1219-1524 / 4000-5000...............................................
..................................................................................................................................3.2 - 4.8V
1524-1829 / 5000-6000........................................................................................................................
.........................................................3.0 - 4.6V 2133-2438 / 7000-8000...............................................
..................................................................................................................................2.8 - 4.3V
2743-3048 / 9000-10,000.....................................................................................................................
.........................................................2.5 - 4.0V

MAP Sensor
PURPOSE
OPERATION
A failure in the MAP sensor circuit should set a DTC 33. See: Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
MAP Sensor Circuit

Circuit Description
Test Description
number.
MAP Sensor
INSTALL OR CONNECT
Sensor Circuit - Manual Update
GROUP ELECTRICAL
AFFECTED VEHICLES
SERVICE INFORMATION
Manual.
Sensor Circuit - Manual Update > Page 1506
Specifications
................................................................... 0.1 - 1.0V
Torque .................................................................................................................................................
......................................................... 45 Nm (33 ft lb)
O2 Sensor

HO2S
PURPOSE
OPERATION
HO2S Circuit
Circuit Description
heat-up on its own.
Test Description
Diagnostic Aids

Oxygen Sensor (HO2S)
O2 Sensor
Caution: ^
Caution: ^
INSTALL OR CONNECT
- HO2S
NOTE: ^
remove.

Oxygen Sensor (HO2S) > Page 1516
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications
Pressure ..............................................................................................................................................
Low pressure .......................................................................................................................................

........................................................................................................................................................
continuity
Page 1520
Page 1521
PURPOSE
LOCATION
OPERATION
Page 1522
PSP Switch Circuit
Circuit Description
Page 1523
de-energized.
Test Description

Electrical Specifications
At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Electrical Specifications > Page 1528
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)
1529

1530
TPS
PURPOSE
OPERATION
is set.
1531
is closed. A failure in the TPS or circuit should set a DTC 21. See: Computers and Control
1532

1533
TP Sensor
TP sensor
INSTALL OR CONNECT

Bulletins > Vehicle Speed Sensor - Manual Correction
GROUP ELECTRICAL

CORRECTION)
AFFECTED VEHICLES
SERVICE INFORMATION
Workshop Manual:
Workshop Manual.
Bulletins > Vehicle Speed Sensor - Manual Correction > Page 1538
Picture 54

Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS
Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse
FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1563
PURPOSE
OPERATION
control system
Specifications
At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page
1570

1571
TPS
PURPOSE
OPERATION
is set.
1572
1573

1574
TP Sensor
TP sensor
INSTALL OR CONNECT

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
87 in lb (10 Nm)

PURPOSE
engine speed.
REMOVE

Protection Shield
REFIT
87 in lb (10 Nm)
46 ft lb (63 Nm)
27 ft lb (37 Nm)

Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Locations
Component Locations

Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Locations > Page 1587
PURPOSE
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Specifications

Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Specifications > Page 1591
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System

Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
speed.
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Cleaner Filter <--> [Air Filter Element] > Component Information > Description and Operation
Air Filter
PURPOSE
OPERATION
chamber.
CONSTRUCTION

Air Cleaner Filter <--> [Air Filter Element] > Component Information > Description and Operation > Page 1600
Air Cleaner Filter <--> [Air Filter Element] > Component Information > Description and Operation > Page 1601
REMOVAL

CLEANING
INSTALLATION
3. Air cleaner hose

Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions
following items:
lubricated.)
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 1606
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB97-01-L003 >
Jun > 97 > Spark Plug Tube - Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB96-01-L005 >
Sep > 96 > Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube -
Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun
> 97 > Spark Plug Tube - Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
No.1 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.2 .....................................................................................................................................................
................................................ 5.7 - 13.1 K Ohms
No.3 .....................................................................................................................................................
................................................ 6.2 - 14.4 K Ohms
No.4 .....................................................................................................................................................
................................................ 5.8 - 13.3 K Ohms
No.5 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.6 .....................................................................................................................................................
................................................ 6.9 - 16.0 K Ohms
Ignition Wire
PURPOSE
CONSTRUCTION
Cable # ................................................................................................................................................
.............................................................. x 1000 ohms
1 ...........................................................................................................................................................
................................................................... 6.4 - 14.9 2 ......................................................................
........................................................................................................................................................ 5.7
- 13.1 3 ................................................................................................................................................
.............................................................................. 6.2 - 14.4 4 ...........................................................
..............................................................................................................................................................
..... 5.8 - 13.3 5 ....................................................................................................................................
.......................................................................................... 6.4 - 14.9 6 ...............................................
..............................................................................................................................................................
................. 6.9 - 16.0
Remove wires.

Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > SB96-01-L005 > Sep > 96 > Spark
Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > SB96-01-L004 > Apr > 96 > Spark
Plug Tube - Replacement Procedure
GROUP: ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube

Component Information > Technical Service Bulletins > All Technical Service Bulletins: > SB9501L002 > Aug > 95 > Spark
Plug Tube - Replacement
GROUP ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
(2.56 in. +/- .02 in).

Component Information > Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube -
Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Component Information > Technical Service Bulletins > All Other Service Bulletins for Spark Plug: > 9305014 > Jul > 93 >
A/T - Clunking Noise on 3-2 Downshift
Band Control Solenoid Valve: All Technical Service Bulletins A/T - Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
4L30-E A/T DOWNSHIFT CLUNK WHEN BRAKING
AFFECTED VEHICLES
1990-91 Trooper II (KT), 1992-93 Trooper (UX) and 1991-93 Rodeo (UC) models equipped with
4L30-E automatic transmission with A/T assembly serial number before 4006228.
NOTE A/T serial number is stamped on the identification plate located on the left side of the
transmission case, above the mode switch.
SERVICE INFORMATION
Affected vehicles may experience a clunking noise during the 3rd to 2nd gear downshift when
braking. The noise is caused by poor band apply solenoid operation. Installing a new, improved
band apply solenoid (see "Parts Information" section of this Service Bulletin) will eliminate this
condition.
Use the existing labor operation. See illustration.
SERVICE PROCEDURE
If a clunking noise is heard during the 3rd to 2nd gear downshift when braking, replace the band
apply solenoid (using parts listed in the "Parts Information" section of this Service Bulletin),
following the procedures in the appropriate Workshop Manual.
PARTS INFORMATION
Component Information > Specifications > Electrical Specifications

..................................................... 50 Mohms or more
Component Information > Specifications > Electrical Specifications > Page 1678
Spark plug gap ....................................................................................................................................

.................................. 0.040 - 0.043 in (1.0 - 1.1 mm)

......................................................... 13 ft lb (18 Nm)

PURPOSE
HEAT RANGE
plug to be hotter.
occur.
INSPECTION
RESISTANCE
50 M ohms
1.05 mm (0.040 in)
SOOTY SPARK PLUGS
Rich fuel mixture.
Lean fuel mixture.

Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > System Diagnosis
Isuzu Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Clearance: > SB00-01-S009 >
Sep > 00 > Engine Valve Train - Ticking Noise
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > SB00-01-S009 > Sep > 00 >
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
System Information > Technical Service Bulletins > Customer Interest for Valve Clearance: > Page 1705
GROUP: ENGINE
NOTE:
AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION

Service Procedure
NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
GROUP: ENGINE
NOTE:

AFFECTED VEHICLES
SERVICE INFORMATION
NOTE:
PARTS INFORMATION
Service Procedure

NOTE:
(Figure 4)
IMPORTANT:
6)
compress).
NOTE:
System Information > Technical Service Bulletins > Page 1715
Stem Diameter:
Intake ...................................................................................................................................................
...................................... 0.2346-0.2323 inches Exhaust .....................................................................
................................................................................................................. 0.2343-0.2323 inches

............................................................................... 45 Valve Clearance:
Intake ...................................................................................................................................................
.................................................................. [01] Exhaust ......................................................................
............................................................................................................................................ [01]

System Information > Technical Service Bulletins > Page 1716

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component
A/C Signal: Locations
LOCATION
Provided from the instrument panel mounted A/C switch.

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor
<--> [Intake Air Temperature Sensor] > Component Information > Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
20°F (-7°C) ..........................................................................................................................................

............................................................... 13.5K ohms 68°F (20°C) .....................................................
..................................................................................................................................................... 3.4K
ohms 100°F (38°C) ..............................................................................................................................
.......................................................................... 1.8K ohms
<--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1724

MAT Sensor
PURPOSE
OPERATION
CONSTRUCTION
REMOVAL
INSTALLATION
torque.
- Wiring connector
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
87 in lb (10 Nm)

PURPOSE
engine speed.
REMOVE

Protection Shield
REFIT
87 in lb (10 Nm)
46 ft lb (63 Nm)
27 ft lb (37 Nm)

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Data Link Connector

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer >
EGR Backpressure Transducer: Locations
Component Locations
Top, L.H. rear side of engine. Item #N2 In figure

Component Information > Locations > Page 1739
EGR Circuit
EGR Backpressure Transducer: Description and Operation
Back Pressure Transducer
PURPOSE
Uses exhaust pressure to regulate the vacuum signal to the Exhaust Gas Recirculation (EGR)
valve.
OPERATION
Under a low load condition such as low speed driving, the exhaust pressure is low. In this state, the
diaphragm in the EGR BPT is pushed down by the spring force and the Back Pressure Transducer
(BPT) valve opens to allow the air into the vacuum passage from the outside.
As a result, the vacuum transmitted to the EGR valve becomes smaller and so does the opening of
the EGR valve.
Thus, less amount of exhaust gas is recirculated to the intake manifold.
Under a high load condition such as high speed driving, on the other hand, the exhaust pressure is
high. By the high exhaust pressure, the diaphragm in the BPT is pushed up and closes its valve. As
the air does not enter the vacuum passage in this state, the vacuum transmitted to the EGR valve
grows larger and so does the opening of the EGR valve.
Thus, larger amount of exhaust gas is recirculated to the intake manifold.

EGR Backpressure Transducer: Testing and Inspection
BPT Valve
1. Remove vacuum hoses (3) from valve.
2. Place finger over "Vacuum Switch Valve (VSV)" fitting on valve and blow into "Exhaust Gas
Recirculation (EGR)" fitting of valve. Air should pass through filter on back of valve.
BPT Valve Test
3. Connect vacuum pump to "VSV" fitting of valve and plug "EGR" fitting.
4. Blow air into "S" fitting. Vacuum pump should hold vacuum.
5. Replace valve if it fails these tests.

EGR Backpressure Transducer: Service and Repair
REMOVAL
1. Vacuum hoses. 2. Back pressure transducer
INSTALLATION
1. Vacuum hoses 2. Back pressure transducer

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >

terminal.
ECM

Inputs And Outputs
PURPOSE
OPERATION
IMPORTANT NOTE!
ECM TESTING
ECM
components.
REMOVAL
INSTALLATION
1. ECM

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Temperature ........................................................................................................................................
............................................................... Resistance
-18°C (0°F) ..........................................................................................................................................

.................................................................. 25K ohms -7°C (20°F) ......................................................
................................................................................................................................................... 13.5K
ohms 4°C (40°F) ..................................................................................................................................
.......................................................................... 7.5K ohms 20°C (68°F) ............................................
..............................................................................................................................................................
3.4K ohms 38°C (100°F) .....................................................................................................................
................................................................................... 1.8K ohms 70°C (160°F) .................................
..............................................................................................................................................................
........... 450 ohms 100°C (212°F) .........................................................................................................
............................................................................................... 185 ohms
ECT Sensor

ECT Sensor
PURPOSE
OPERATION
CONSTRUCTION
266°F).
ECT Sensor
REMOVAL
INSTALLATION
torque
system.
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications
Idle Air Control Valve: Specifications
Resistance Value
Between terminals A and B..................................................................................................................

..................................................................40-80 ohms
Between terminals C and D..................................................................................................................

..................................................................40-80 ohms
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 1760
Idle Air Control Valve: Locations
Throttle Body

Idle Air Control Valve: Description and Operation
IAC Valve
PURPOSE
Allows the Engine Control Module (ECM) control over idle speed.
OPERATION
The Idle Air Control (IAC) Valve is activated by the ECM to control engine idle speed while
preventing stalls due to changes in engine load. The valve is mounted in the intake manifold to
regulate the amount of bypass air around the throttle valve. The ECM sends voltage pulses to IAC
motor windings, causing IAC valve pintle to move in or out a given distance (a step or count) for
each pulse, as needed to obtain the desired idle speed.
During idle, proper IAC valve position is "learned" by the ECM based on battery voltage, coolant
temperature and engine rpm. If the position is incorrect, the ECM will command a reset which will
occur when vehicle speed is about 30 mph.
If rpm drops below a specified value and the throttle is closed, the ECM senses a near stall
condition and will calculate a new valve position to prevent stalling.
Idle Air Control Valve: Testing and Inspection
Chart C-2C IAC System Check

Circuit Description
The engine control module (ECM) controls engine idle speed with idler air control (IAC) valve. To
increase idle speed, the ECM retracts the IAC valve pintle away from its seat, allowing more air to
bypass the throttle bore. To decrease idle speed, it extends the IAC valve pintle towards its seat,
reducing bypass air flow. A "Scan tool" will read the ECM commands to the IAC valve in counts.
Higher counts indicate more air bypass (higher idle). Lower counts indicate less air is allowed to
bypass (lower idle).
Test Description
Number below refer to circled numbers on the diagnostic chart.
1. The IAC tester is used to extend and retract the IAC valve. Valve movement is verified by a
engine speed change. If no change in engine speed occurs, the valve can be retested when
removed from the throttle body.
2. This step checks the quality of the IAC movement in step 1. Between 700 revolution per minute
(rpm) and about 1500 rpm, the engine speed should change smoothly with each flash of the tester
light in both extend and retract. If the IAC valve is retracted beyond the control range (about 1500
rpm), it may take many flashes in the extend position before engine speed will begin to drop. This
is normal on certain engines, fully extending IAC may cause engine stall. This may be normal.
3. Steps 1 and 2 verified proper IAC valve operation. This step checks the IAC circuits. Each lamp
on the node light should flash red and green while the IAC valve is cycled. While the sequence of
color is not important if either light "OFF" or does not flash red and green, check the circuits for
faults, beginning with poor terminal contacts.
Diagnostic Aids
A slow, unstable, or fast idle may be caused by a non-IAC system problem that cannot overcome
by the IAC valve. Out of control range IAC "Scan tool" counts will be above 60 if idle is too low, and
zero counts If Idle is too high. The following checks should be made to repair a non-IAC system
problem.
Vacuum Leak (High Idle) If idle is too high, stop the engine. Fully extend (low) IAC with tester. Start
engine. If idle speed is above 800 rpm, locate and correct vacuum leak including PCV system. Also
check for binding of throttle blade or linkage.
Lean heated oxygen sensor signal (High Air/Fuel Ratio) The idle speed may be too high or too low.
Engine speed may vary up and down and disconnecting the AC valve does not help. Diagnostic
trouble code 44 may be set. "Scan tool" oxygen (02) voltage will be less than 100 mV (.1 volt).
Check for low regulated fuel pressure, water in fuel, or a restricted injector.
Rich heated oxygen sensor signal (Low Air/Fuel Ratio) The idle speed will be too low. "Scan tool"
IAC counts will usually be above 80. System is obviously rich and may exhibit black smoke in
exhaust. "Scan tool" O2 voltage will be fixed about 750 mV (.75 volt). Check for high fuel pressure,
leaking or sticking Injector. Silicon contaminated heated oxygen sensor will "Scan tool" an O2
voltage slow to respond.
Throttle Body Remove IAC valve and inspect bore for foreign material.
IAC Valve Electrical Connections IAC valve connections should be carefully checked for proper
contact.
PCV Valve An incorrect or faulty PCV valve may result in an incorrect idle speed.
If intermittent poor driveability or idle symptoms are resolved by disconnecting the IAC, carefully
recheck connections, valve terminal resistance, or replace IAC.
Idle Air Control Valve: Service and Repair
IDLE AIR CONTROL (IAC) VALVE
REMOVAL
Preparation: ^Battery negative cable.
1. Idle air control (IAC) valve electrical connector 2. IAC valve attaching screw 3. IAC valve
assembly
On IAC valves that have been in service: Do not push or pull on the IAC valve pintle. The force
required to move the pintle may damage the threads on the worm drive. Also, Do not soak the IAC
valve in any liquid cleaner or solvent, as damage may result.
CLEANING AND INSPECTION
^ Clean IAC valve O-ring sealing surface, pintle valve seat and air passage.
- Use carburetor cleaner and a parts cleaning brush to remove carbon deposits. Do Not use a
cleaner that contains methyl ethyl ketone. It is an extremely strong solvent, and not necessary for
this type of deposit.
- Shiny spots on the pintle or seat are normal, and do not indicate misalignment or a bent pintle
shaft.
- If air passage has heavy deposits, remove throttle body for complete cleaning.
^ Inspect IAC valve O-ring for cuts, cracks or distortion. Replace if damaged.
CAUTION: If installing a new IAC valve, be sure to replace it with an identical part. IAC valve pintle
shape and diameter are designed for the specific application.
IAC Valve
INSTALLATION
If installing a new IAC valve, measure the distance from the tip of the IAC pintle to the mounting
flange. If it is greater than 28 mm, use finger pressure to slowly retract the pintle. The force
required to retract the pintle of a "New Valve" will not cause damage to the valve.
1. IAC valve assembly 2. IAC valve attaching screw 3. Idle air control valve electrical connector
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Fuse Panel

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 1768
PURPOSE
OPERATION
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >

PURPOSE
LOCATION
OPERATION

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Absolute Pressure
Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications
Below 305 / 1000..................................................................................................................................

........................................................3.8 - 5.5V 305-610 / 1000-2000....................................................
.................................................................................................................................3.6 - 5.3V
914-1219 / 3000-4000..........................................................................................................................
.........................................................3.3 - 5.0V 1219-1524 / 4000-5000...............................................
..................................................................................................................................3.2 - 4.8V
1524-1829 / 5000-6000........................................................................................................................
.........................................................3.0 - 4.6V 2133-2438 / 7000-8000...............................................
..................................................................................................................................2.8 - 4.3V
2743-3048 / 9000-10,000.....................................................................................................................
.........................................................2.5 - 4.0V
Sensor <--> [Manifold Pressure/Vacuum Sensor] > Component Information > Specifications > Page 1777

MAP Sensor
PURPOSE
OPERATION
A failure in the MAP sensor circuit should set a DTC 33. See: Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Engine Control System/DTC 33
MAP Sensor Circuit

Circuit Description
Test Description
number.
MAP Sensor
INSTALL OR CONNECT
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > O2 Sensor Circuit - Manual Update
GROUP ELECTRICAL
AFFECTED VEHICLES
SERVICE INFORMATION
Manual.
Information > Technical Service Bulletins > O2 Sensor Circuit - Manual Update > Page 1787

................................................................... 0.1 - 1.0V
Torque .................................................................................................................................................
......................................................... 45 Nm (33 ft lb)
O2 Sensor

HO2S
PURPOSE
OPERATION
HO2S Circuit
Circuit Description
heat-up on its own.
Test Description
Diagnostic Aids

Information > Service and Repair > Heated Oxygen Sensor (HO2S)
O2 Sensor
Caution: ^
Caution: ^
INSTALL OR CONNECT
- HO2S
NOTE: ^
remove.


Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 1797
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch
Pressure ..............................................................................................................................................
Low pressure .......................................................................................................................................

........................................................................................................................................................
continuity

PURPOSE
LOCATION
OPERATION
PSP Switch Circuit
Circuit Description
de-energized.
Test Description

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Specifications

terminal.
and Control Systems > Engine Control Module > Component Information > Specifications > Page 1809
ECM

Inputs And Outputs
PURPOSE
OPERATION
IMPORTANT NOTE!
ECM TESTING
ECM
components.
REMOVAL
INSTALLATION
1. ECM

and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Fuse Panel

and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1816
PURPOSE
OPERATION
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches -
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
87 in lb (10 Nm)
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1821

PURPOSE
engine speed.
REMOVE

Protection Shield
REFIT
87 in lb (10 Nm)
46 ft lb (63 Nm)
27 ft lb (37 Nm)

Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications
Temperature ........................................................................................................................................
............................................................... Resistance
-18°C (0°F) ..........................................................................................................................................

.................................................................. 25K ohms -7°C (20°F) ......................................................
................................................................................................................................................... 13.5K
ohms 4°C (40°F) ..................................................................................................................................
.......................................................................... 7.5K ohms 20°C (68°F) ............................................
..............................................................................................................................................................
3.4K ohms 38°C (100°F) .....................................................................................................................
................................................................................... 1.8K ohms 70°C (160°F) .................................
..............................................................................................................................................................
........... 450 ohms 100°C (212°F) .........................................................................................................
............................................................................................... 185 ohms
Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 1827
ECT Sensor

ECT Sensor
PURPOSE
OPERATION
CONSTRUCTION
266°F).
ECT Sensor
REMOVAL
INSTALLATION
torque
system.
Computers and Control Systems > Intake Air Temperature Sensor <--> [Intake Air Temperature Sensor] > Component
Temperature ........................................................................................................................................
............................................................... Resistance
20°F (-7°C) ..........................................................................................................................................

............................................................... 13.5K ohms 68°F (20°C) .....................................................
..................................................................................................................................................... 3.4K
ohms 100°F (38°C) ..............................................................................................................................
.......................................................................... 1.8K ohms

MAT Sensor
PURPOSE
OPERATION
CONSTRUCTION
REMOVAL
INSTALLATION
torque.
- Wiring connector
Computers and Control Systems > Manifold Absolute Pressure Sensor <--> [Manifold Pressure/Vacuum Sensor] >
Below 305 / 1000..................................................................................................................................

........................................................3.8 - 5.5V 305-610 / 1000-2000....................................................
.................................................................................................................................3.6 - 5.3V
914-1219 / 3000-4000..........................................................................................................................
.........................................................3.3 - 5.0V 1219-1524 / 4000-5000...............................................
..................................................................................................................................3.2 - 4.8V
1524-1829 / 5000-6000........................................................................................................................
.........................................................3.0 - 4.6V 2133-2438 / 7000-8000...............................................
..................................................................................................................................2.8 - 4.3V
2743-3048 / 9000-10,000.....................................................................................................................
.........................................................2.5 - 4.0V

MAP Sensor
PURPOSE
OPERATION
A failure in the MAP sensor circuit should set a DTC 33. See: Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Engine Control System/DTC 33
MAP Sensor Circuit

Circuit Description
Test Description
number.
MAP Sensor
INSTALL OR CONNECT
Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > O2 Sensor
Circuit - Manual Update
GROUP ELECTRICAL
AFFECTED VEHICLES
SERVICE INFORMATION
Manual.
Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > O2 Sensor
Circuit - Manual Update > Page 1850
Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications

................................................................... 0.1 - 1.0V
Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications >
Page 1853
Torque .................................................................................................................................................
......................................................... 45 Nm (33 ft lb)
Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Page 1854
O2 Sensor

HO2S
PURPOSE
OPERATION
HO2S Circuit
Circuit Description
heat-up on its own.
Test Description
Diagnostic Aids

Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S)
O2 Sensor
Caution: ^
Caution: ^
INSTALL OR CONNECT
- HO2S
NOTE: ^
remove.

Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 1860
Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications
Pressure ..............................................................................................................................................
Low pressure .......................................................................................................................................

........................................................................................................................................................
continuity
Computers and Control Systems > Power Steering Pressure Switch > Component Information > Specifications > Page 1864

PURPOSE
LOCATION
OPERATION
PSP Switch Circuit
Circuit Description
de-energized.
Test Description

Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical
Specifications
At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)
Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1873

TPS
PURPOSE
OPERATION
is set.
is closed. A failure in the TPS or circuit should set a DTC 21. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Engine Control System/DTC
21

TP Sensor
TP sensor
INSTALL OR CONNECT

Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Vehicle
Speed Sensor - Manual Correction
GROUP ELECTRICAL

CORRECTION)
AFFECTED VEHICLES
SERVICE INFORMATION
Workshop Manual:
Workshop Manual.
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Vehicle
Speed Sensor - Manual Correction > Page 1882
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page
1883
Picture 54

Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Instructions > Page 1886
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS
Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse
FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1907
PURPOSE
OPERATION
control system
Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >

At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)

TPS
PURPOSE
OPERATION
is set.
is closed. A failure in the TPS or circuit should set a DTC 21. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Engine Control System/DTC
21

TP Sensor
TP sensor
INSTALL OR CONNECT

Isuzu Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Technical Service Bulletins > Vehicle Speed Sensor - Manual Correction
GROUP ELECTRICAL

CORRECTION)
AFFECTED VEHICLES
SERVICE INFORMATION
Workshop Manual:
Workshop Manual.
Component Information > Technical Service Bulletins > Vehicle Speed Sensor - Manual Correction > Page 1922
Picture 54

Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair



Component Information > Diagrams > Page 1947
PURPOSE
OPERATION
control system
Isuzu Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Catalytic Converter: Locations
LOCATION
Two (2) catalytic converters are used downstream of the exhaust manifold to reduce oxides of
nitrogen (NOx) and oxidize hydrocarbons (HC) and carbon monoxide (CO).
Information > Description and Operation > California
Catalytic Converter: Description and Operation California
PURPOSE
Reduces exhaust emissions.
The rear three-way converter contains the catalyst elements platinum, rhodium and palladium
which promote oxidation and reduction reactions at high temperatures. Emissions are converted
into carbon dioxide, water vapor and nitrogen.
An oxidizing catalyst, Pre Converter, mounted directly in the exhaust manifold, is also used to
oxidize excess hydrocarbons that occur in the exhaust when the engine is cold.
Information > Description and Operation > California > Page 1954
Catalytic Converter: Description and Operation Federal
Three-Way Catalytic Converter
PURPOSE
To reduce exhaust emissions of NOx, HC, and CO.
OPERATION
A three-way catalytic converter is used downstream of the exhaust manifold to reduce oxides of
nitrogen (NOx) and oxidize hydrocarbons (HC) and carbon monoxide (CO). Emissions are
converted into carbon dioxide, water vapor and nitrogen.
CONSTRUCTION
The converter contains the catalyst elements platinum, rhodium and palladium which promote
oxidation and reduction reactions at high temperatures.
Catalytic Converter: Testing and Inspection
CATALYTIC CONVERTER INSPECTION
1. Visually inspect exterior of converter. If severe damage is noted, such a dented, crushed or
rusted out shell, replace converter.
2. Whenever converter is removed from vehicle, check ceramic element through exhaust inlet and
outlet. If element is clogged, melted or otherwise damaged, replace converter.
Exhaust System Back Pressure Check (Using Oxygen Sensor Mounting Hole)
RESTRICTED EXHAUST SYSTEM CHECK AT OXYGEN SENSOR
1. Remove oxygen sensor.
2. In place of the sensor, install a Boroughs exhaust backpressure tester (BT8515 or BT8603) or
equivalent
3. With engine idling at normal operating temperature, the gauge reading should not exceed 8.6
kPa (1.25 psi).
4. Increase engine speed to 2000 rpm. Gauge reading should not exceed 20.7 kPa (3 psi).
5. If backpressure at either speed exceeds specification, a restricted exhaust system is indicated.
6. Inspect exhaust system for a collapsed pipe, heat distress or possible internal muffler failure.
7. If no obvious reasons for excessive exhaust system backpressure are found, suspect a
restricted catalytic converter.
8. After completing test, coat threads of oxygen sensor with anti-seize compound prior to
reinstallation.
Information > Service and Repair > Federal
Catalytic Converter: Service and Repair Federal
Exhaust System

Information > Service and Repair > Federal > Page 1958
Catalytic Converter: Service and Repair California
TWC
Exhaust System

Information > Service and Repair > Federal > Page 1959
Pre-Cat
Isuzu Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Canister Purge Control Solenoid <--> [Canister Purge Solenoid] > Component Information >
Specifications
Evaporative Emission Canister Purge Control Solenoid: Specifications
Resistance Value .................................................................................................................................
............................................................. over 20 ohms
Evaporative Emission Canister Purge Control Solenoid: Locations
Component Locations
Top of engine at Right Rear. Item #14 in figure

Evaporative Emission Canister Purge Control Solenoid: Description and Operation
Evaporative Vacuum Diagram
PURPOSE
Allows ECM to control when canister purge operation occurs.
OPERATION
Evaporate emission canister purge is controlled by a solenoid that allows manifold and/or ported
vacuum to purge the canister when energized. The Engine Control Module (ECM) supplies a
ground to energize the solenoid (purge "ON"). The purge solenoid control by the ECM is turned
"ON" or "OFF" under specific engine conditions. The purge solenoid is turned "ON" when all of the
following conditions are met. ^
Data link connector is ungrounded.
^ Engine run time after start more than 20 seconds.
^ Engine coolant temperature above 60'C.
^ Vehicle speed is above 9 miles per hour.
Also, if the diagnostic test terminal is grounded with the engine stopped, the purge solenoid is
energized (purge "ON").
Evaporative Emission Canister Purge Control Solenoid: Testing and Inspection
Canister Purge Solenoid Circuit

Chart C-3 Canister Purge Valve Check
Circuit Description
Evaporate emission canister purge is controlled by a solenoid that allows manifold and/or ported
vacuum to purge the canister when energized. The Engine Control Module (ECM) supplies a
ground to energize the solenoid (purge "ON"). The purge solenoid control by the ECM is turned
"ON" or "OFF" under specific engine conditions. The purge solenoid is turned "ON" when all of the
following conditions are met.
^ Data link connector is ungrounded. ^ Engine run time after start more than 20 seconds. ^ Engine
coolant temperature above 60'C. ^ Vehicle speed is above 9 miles per hour.
Also, if the diagnostic test terminal is grounded with the engine stopped, the purge solenoid is
energized (purge "ON").
Test Description
Numbers below refer to circled number's on the diagnostic chart.
1. Check to see if the solenoid is opened or closed. The solenoid is normally de-energized in this
step, so it should be closed.
2. Checks to determine if solenoid was open due to electrical CKT problem or defective solenoid.
3. Completes functional check by grounding test terminal. This should normally energize the
solenoid opening the valve which should allow the vacuum to drop (purge "ON").
Diagnostic Aids
Make a visual check of vacuum hose(s). Check throttle body for possible cracked, or plugged
vacuum block. Malfunction indicator lamp for possible mechanical problem.
Evaporative Emission Control Canister > Component Information > Locations
Evaporative Emission Control Canister: Locations
Component Locations
On R.H. fender apron. Item N15 in figure.

Evaporative Emission Control Canister > Component Information > Locations > Page 1972
Evaporative Emission Control Canister: Description and Operation
Fuel Vapor Canister
PURPOSE
Stores fuel vapor until purge operation occurs.
OPERATION
When the Engine Control Module (ECM) energizes the solenoid valve, manifold vacuum draws air
through fitting 2 on the canister. Fresh air being drawn into the bottom of the canister, "flushes"
(purges) the canister of fuel vapors. The vapors flow into the engine and are burned in the
combustion process.
Evaporative Emission Control Canister > Component Information > Testing and Inspection > Canister Visual Check
Evaporative Emission Control Canister: Testing and Inspection Canister Visual Check
Fuel Vapor Canister
1. Replace canister if cracked or otherwise damaged.
2. Replace canister if fuel is leaking from the bottom.
3. If dirty, plugged or damaged, replace filter at bottom of canister.

Evaporative Emission Control Canister > Component Information > Testing and Inspection > Canister Visual Check > Page
1975
Evaporative Emission Control Canister: Testing and Inspection Results of Incorrect Operation
Poor idle, stalling and poor driveability can be caused by: ^
Inoperative purge solenoid.
^ Damaged canister.
^ Hoses split, cracked and/or not connected to the proper tubes.
Evidence of fuel loss or fuel vapor odor can be caused by: ^
Liquid fuel leaking from fuel lines, or fuel pump.
^ Cracked or damaged canister.
^ Disconnected, misrouted, kinked, deteriorated or damaged vapor hoses, or control hoses.
If the solenoid is always open, the canister can purge to the intake manifold at all times. This can
allow extra fuel at idle or during warm-up, which can cause rough or unstable idle, or too rich
operation. If the solenoid is always closed, the canister can become over-loaded, resulting in fuel
odor.
Evaporative Emission Control Canister > Component Information > Testing and Inspection > Page 1976
Evaporative Emission Control Canister: Service and Repair
1. Hoses from canister. Mark hoses to install on new canister. 2. Canister.
INSTALL OR CONNECT
1. Canister as removed. 2. Hoses. Make sure connections are correct.
CANISTER HOSES
Refer to Vehicle Emission Control Information label for routing of canister hoses. When replacing
hoses, use 6148M or its equivalent.
Isuzu Workshop Manuals > Powertrain Management > Emission Control Systems > EGR Vacuum Switch Valve (VSV)
Solenoid <--> [Exhaust Gas Recirculation] > EGR Backpressure Transducer > Component Information > Locations
EGR Backpressure Transducer: Locations
Component Locations
Top, L.H. rear side of engine. Item #N2 In figure

Solenoid <--> [Exhaust Gas Recirculation] > EGR Backpressure Transducer > Component Information > Locations > Page
1981
EGR Circuit
1982
EGR Backpressure Transducer: Description and Operation
Back Pressure Transducer
PURPOSE
Uses exhaust pressure to regulate the vacuum signal to the Exhaust Gas Recirculation (EGR)
valve.
OPERATION
Under a low load condition such as low speed driving, the exhaust pressure is low. In this state, the
diaphragm in the EGR BPT is pushed down by the spring force and the Back Pressure Transducer
(BPT) valve opens to allow the air into the vacuum passage from the outside.
As a result, the vacuum transmitted to the EGR valve becomes smaller and so does the opening of
the EGR valve.
Thus, less amount of exhaust gas is recirculated to the intake manifold.
Under a high load condition such as high speed driving, on the other hand, the exhaust pressure is
high. By the high exhaust pressure, the diaphragm in the BPT is pushed up and closes its valve. As
the air does not enter the vacuum passage in this state, the vacuum transmitted to the EGR valve
grows larger and so does the opening of the EGR valve.
Thus, larger amount of exhaust gas is recirculated to the intake manifold.

1983
EGR Backpressure Transducer: Testing and Inspection
BPT Valve
1. Remove vacuum hoses (3) from valve.
2. Place finger over "Vacuum Switch Valve (VSV)" fitting on valve and blow into "Exhaust Gas
Recirculation (EGR)" fitting of valve. Air should pass through filter on back of valve.
BPT Valve Test
3. Connect vacuum pump to "VSV" fitting of valve and plug "EGR" fitting.
4. Blow air into "S" fitting. Vacuum pump should hold vacuum.
5. Replace valve if it fails these tests.

1984
EGR Backpressure Transducer: Service and Repair
REMOVAL
1. Vacuum hoses. 2. Back pressure transducer
INSTALLATION
1. Vacuum hoses 2. Back pressure transducer

Solenoid <--> [Exhaust Gas Recirculation] > EGR Vacuum Switching Valve <--> [EGR Control Solenoid] > Component
EGR Vacuum Switching Valve: Specifications
Resistance Value .................................................................................................................................
................................................................ 33-39 ohms
EGR Vacuum Switching Valve: Locations
Component Locations
On the common chamber. Item #12 in figure.

EGR Vacuum Switching Valve: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
EGR Vacuum Switching Valve: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS
Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse
FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair

EGR Circuit
Information > Diagrams > Page 2012
EGR Vacuum Switching Valve: Description and Operation
PURPOSE
Allows Engine Control Module (ECM) control over Exhaust Gas Recirculation (EGR) operation.
OPERATION
The EGR vacuum switching valve (VSV) is operated by ECM and is normally closed to prevent the
EGR valve from opening: -
When the engine is cold.
- When throttle valve is at idle position.
- When manifold air temperature is low.
- When intake manifold pressure is low.

EGR Vacuum Switching Valve: Testing and Inspection
1. Disconnect vacuum hoses from solenoid valve.
2. Turn ignition key "OFF" and disconnect solenoid electrical connector.
3. Using an ohmmeter, check resistance between solenoid terminals.
4. If resistance is between 33 and 39 ohms, proceed.
5. If resistance is not between 33 and 39 ohms, replace solenoid.
6. Blow into tube"2". Air should pass to filter (not through tube "1".
7. Reconnect electrical connector.
8. Turn key "ON" and ground Diagnosis Switch Terminal.
9. Blow air into tube "2". Air should pass to tube "1".
10. Replace Vacuum Switch Valve (VSV) if it fails tests.

EGR Vacuum Switching Valve: Service and Repair
REMOVAL
1. Electrical connector 2. Vacuum hoses from vacuum switch valve (VSV) 3. Two fasteners hold
VSV to intake manifold.
INSTALLATION
1. VSV and Retaining bolts. 2. Vacuum hoses 3. Electrical connector

Solenoid <--> [Exhaust Gas Recirculation] > EGR Valve > Component Information > Specifications
EGR Valve: Specifications
Vacuum to open ..................................................................................................................................

..................................................................... 10 in Hg
Solenoid <--> [Exhaust Gas Recirculation] > EGR Valve > Component Information > Specifications > Page 2018
EGR Valve: Locations
Component Locations
Top, L.H. rear side of engine.

EGR Valve: Description and Operation
EGR Valve
PURPOSE
Allows a metered amount of exhaust to recycle in to the intake stream.
OPERATION
This valve is controlled by a flexible diaphragm which is spring loaded to hold the valve closed.
Vacuum applied to the top side of the diaphragm overcomes spring pressure and opens the valve
in the exhaust port, allowing exhaust gas into the intake manifold and thus to the cylinders.
EGR Valve: Testing and Inspection
1. Warm engine to operating temperature (120° F / 60° C).
2. Place finger on on EGR valve diaphragm and accelerate engine, diaphragm should move.
3. Disconnect vacuum hose from EGR valve.
4. Using a vacuum pump, apply 10" of vacuum to the valve. It should move and engine should run
poorly or stall.
5. If valve passes above test use SYSTEM TEST CHART C-7A. See: Testing and Inspection If
valve fails, replace valve.
Solenoid <--> [Exhaust Gas Recirculation] > EGR Valve > Component Information > Service and Repair > Removal and
Replacement
EGR Valve: Service and Repair Removal and Replacement
REMOVAL
1. Air cleaner duct assembly. 2. Vacuum hoses from Exhaust Gas Recirculation (EGR) valve. 3.
EGR pipe 4. Retaining bolts (2) from valve. 5. EGR valve & gasket.
INSTALLATION
1. EGR valve & New gasket. 2. Retaining bolts to valve. 3. EGR pipe. 4. Vacuum hoses to EGR
valve. 5. Air cleaner dust assembly.
Solenoid <--> [Exhaust Gas Recirculation] > EGR Valve > Component Information > Service and Repair > Removal and
Replacement > Page 2023
EGR Valve: Service and Repair Passage Inspection and Service
If Exhaust Gas Recirculation (EGR) passages in the inlet manifold indicate excessive build-up of
deposits, the passages should be cleaned. Care should be taken to ensure that all loose particles
are completely removed, to prevent them from clogging the EGR valve, or from being ingested into
the engine.
Do not wash EGR valve in solvents or de greaser as permanent damage to valve diaphragm may
result. Also, sand blasting of the valve is not recommended, since this can affect the operation of
the valve.
Isuzu Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations
Positive Crankcase Ventilation Valve: Locations
Component Locations
Top, L.H. side of engine.

Isuzu Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations > Page 2028
Positive Crankcase Ventilation Valve: Testing and Inspection
PCV VALVE TESTING
1. Remove PCV valve from valve cover but leave attached to hose.
2. Start engine and run at idle.
3. Check for vacuum at the valve by placing a finger over the open end. Strong vacuum should be
present.
4. If there is no vacuum, stop engine and check for plugged hose, manifold port or PCV valve.
5. Inspect PCV valve metered orifice and clean or replace valve as required. Shake valve and
listen for rattle. Replace valve if it does not rattle. Replace hose if defective.
6. Clean manifold port if needed.

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations
Component Locations

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations > Page 2034
PURPOSE
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions
following items:
lubricated.)
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 2038
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
speed.
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner
Filter <--> [Air Filter Element] > Component Information > Description and Operation
Air Filter
PURPOSE
OPERATION
chamber.
CONSTRUCTION

REMOVAL

CLEANING
INSTALLATION
3. Air cleaner hose

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Fuel System - Top Tier Detergent Gasoline Information
Fuel: Technical Service Bulletins Fuel System - Top Tier Detergent Gasoline Information
Information IB06-02-S001 Top Tier Detergent Gasoline Top Tier Detergent Gasoline
Affected Vehicles
Service Information
A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel
marketers. This gasoline meets detergency standards developed by four automotive companies.
All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the
"Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit
related concerns may especially benefit from use of TOP TIER Detergent Gasoline.
Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards
As of July 1 2006, all grades of the following gasoline brands meet the TOP TIER Detergent
Gasoline Standards:
^ Chevron
Chevron has markets in 29 states in the West, Southwest and South, as well as in Alaska and
Hawaii.
ALL grades of Chevron with Techron gasoline meet TOP TIER Detergent Gasoline Standards.
^ Shell
Shell Oil Products has a network of nearly 7,000 branded gasoline stations in the Western United
States.
Shell Oil Company markets branded products through more than 10,000 stations in the Eastern
and Southern United States.
^ Kwik Trip, Inc. offers gasoline at Kwik Trip convenience stores in Minnesota and Wisconsin and
Kwik Star convenience stores in Iowa.
^ Quik Trip (not to be confused with Kwik Trip)
Quik Trip operates convenience stores and travel centers in a number of metropolitan areas:
^ Conoco has over 4,000 stations located in 33 states.
^ Phillips 66 has locations in 32 states across the nation.
^ 76 has over 2,700 stations located throughout the country.
^ Entec Stations offer gasoline through stations located in the greater Montgomery, Alabama area.
^ MFA Oil Company offers gasoline at "Break Time" convenience stores located throughout
Missouri.
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Fuel System - Top Tier Detergent Gasoline Information > Page 2057
^ The Somerset Refinery, Inc. offers gasoline at Somerset Oil stations in Kentucky.
What is TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new,
voluntary deposit control standards developed by four automotive companies that exceed the
detergent requirements imposed by the EPA.
Where Can TOP TIER Detergent Gasoline Be Purchased?
The TOP TIER program began on May 3, 2004. Some fuel marketers have already joined and
have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel
marketers will offer this product. Once fuel marketers make public announcements, they will appear
on a list of brands that meet the TOP TIER standards.
Who developed TOP TIER Detergent Gasoline standards?
TOP TIER Detergent Gasoline standards were developed by four automotive companies: BMW,
General Motors, Honda and Toyota.
Why was TOP TIER Detergent Gasoline developed?
TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in
gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However,
the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to
meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is
required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to
differentiate their product.
What are the benefits of TOP TIER Detergent Gasoline?
TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest
Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and
performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce
deposit related concerns.
Disclaimer
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Description and Operation
Fuel Filler Cap: Description and Operation
Fuel Filler Cap
PURPOSE
Seals the fuel filler inlet, allows air to enter the fuel and, and vents excessive fuel tank pressure
OPERATION
The fuel filler cap has both a vacuum valve and a pressure valve. If a negative pressure develops
in the fuel tank, the ambient valve of the fuel filler cap will open. Ambient air will flow into the fuel
tank through the vacuum valve.
When the development of a positive pressure in the fuel tank exceeds a specific value, the
pressure valve will open and the fuel vapor will escape into the atmosphere. This valve does not
function under normal operating conditions.
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service Precautions
following items:
lubricated.)
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service Precautions > Page 2065
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Fuel Injector: Locations
Top Center of engine Attached to fuel rail.

Fuel Injector: Description and Operation
Fuel Injector
PURPOSE
Injects a metered amount of highly atomized fuel at the back side of the intake valve.
DESCRIPTION
There are 6 injectors (one for each cylinder), each of which is installed between the cylinder head
and delivery pipe. It injects fuel into the intake port of a single engine cylinder according to the
signal from Engine Control Module (ECM).
CONSTRUCTION
The injector assembly is a high impedance (12.2 ohms) , solenoid-operated, normally closed
injection nozzle.
Fuel Injector
FUEL INJECTOR OPERATION
When the solenoid coil of the injector is energized by ECM, it becomes an electromagnet and
attracts the plunger. This allows fuel to flow past the ball valve, through flow director plate, into
cylinder. As the lift stroke of the ball valve of the injector is set constant, the amount of fuel injected
at one time is determined by the length of time during which the solenoid coil is energized (injection
time).
FUEL INJECTOR DRIVER OPERATION
The method of turning the Fuel Injectors "ON" and "OFF" is called a "Peak" and "Hold" Driver
System.
The ECM uses a transistor to "Peak" Injector to open it. A second set of Injector Drivers will "Hold"
the Injectors open for the calculated pulse width. The ECM has three (3) Injector Drivers, they are
labeled A, B, and C inside the ECM. Injector Driver "A" is used to open the Injector initially (Peak)
and depending on available battery positive voltage Injector Drive "B" or "C" is used to "Hold" the
Injector for the amount of time necessary to inject the proper amount of fuel into the cylinder. A
resistor module in part of the Injector Driver circuits to protect the Injector Drivers from high current
(amps). If one of the Driver circuits become "Open" the vehicle will not start. Diagnosis of the
Injector driver circuits are done with Chart A-3 "Cranks But Won't Start". See: Computers and
Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Lettered
Diagnostic Charts/A - Charts/A-3 ~ Engine Cranks But Will Not Start
Fuel Injector: Testing and Inspection
Chart C-2A Injector Balance Test
Injector Balance Test
Injector Balance Test Example

The injector balance tester is a tool used to turn the injector on for a precise amount of time, thus
spraying a measured amount of fuel into the manifold. This causes a drop in fuel rail pressure that
we can record and compare between each injector. All injectors should have the same amount of
pressure drop (- 10 kPa). Any injector with a pressure drop that is 10 kPa (or more) greater or less
than the average drop of the other injectors should be considered faulty and replaced.
NOTES:
^ It will be necessary to remove the intake plenum to perform this procedure. Refer to intake
plenum remove procedure in this section. It will also be
necessary to install the Intake Manifold Diagnostic Plate J 39185 to enable the engine to be run
with the plenum removed. Refer to Powertrain Management/Fuel Delivery and Air Induction/Intake
Air Plenum/Service and Repair.
^ The entire test should NOT be repeated more than once without running the engine to prevent
flooding. (This includes any retest on faulty
injectors). To run the engine with the intake plenum removed use the Intake Manifold Diagnostic
Plate.
STEP 1
- Engine "cool down" period (10 minutes) is necessary to avoid irregular readings due to "Hot
Soak" fuel boiling. With ignition "OFF" connect fuel
gauge J 347301 or equivalent to fuel pressure tap. Wrap a shop towel around fitting while
connecting gage to avoid fuel spillage. Refer to Powertrain Management/Fuel Delivery and Air
Induction/Testing and Inspection/Procedures.
- Disconnect harness connectors at all injectors, and connect injector tester J 34730-3, or
equivalent, to one injector. Follow manufacturers
instructions for use of adaptor harness. Ignition must be "OFF" at least 10 seconds to complete
engine control module shutdown cycle. Fuel pump should run about 2 seconds after ignition is
turned "ON". At this point, insert clear tubing attached to vent valve into a operation. Repeat this
step until all air is bled from gauge.
STEP 2
- Turn ignition "OFF" for 10 seconds and then "ON" again to get fuel pressure to its maximum.
Record this initial pressure reading. Energize tester
one time and note pressure drop at its lowest point (Disregard any slight pressure increase after
drop hits low point). By subtracting this second pressure reading from the initial pressure, we have
the actual amount of injector pressure drop.
STEP 3
- Repeat step 2 on each injector and compare the amount of drop. Usually, good injectors will have
virtually the same drop. Retest any injector that
has a pressure difference of 10 kPa, either more or less than the average of the other injectors on
the engine. Replace any injector that also fails the retest. If the pressure drop of all injectors is
within 10 kPa of this average, the injectors appear to be following properly.
Fuel Injector: Service and Repair
Before starting disconnect battery ground cable.
Fuel Injector Rail
REMOVAL
1. Remove air cleaner assy. 2. Disconnect accelerator cable from throttle body and cable brackets
and remove cable. 3. Disconnect canister vacuum hose from Vacuum Switching Valve (VSV). 4.
Disconnect Air vacuum hose from common chamber.. 5. Disconnect vacuum booster hose from
common chamber duct. 6. Disconnect Connectors from Manifold Absolute Pressure sensor,
canister Vacuum Switching Valve (VSV), Exhaust Gas Recirculation VSV,
Intake Air Temperature and ground cable.
7. Remove spark plug wires from cylinder heads. 8. Disconnect three connectors from Ignition
Control Module assembly, Remove three Electronic Ignition bracket fixing bolts, and remove
Electronic Ignition assembly with plug wires.
9. Remove four bolts from throttle valve housing and remove housing. 10. Disconnect EVAP
canister and Exhaust Gas Recirculation VSV hoses from throttle body. 11. Disconnect Positive
Crankcase Ventilation (PCV) hose from common chamber duct. 12. Disconnect fuel pressure
control vacuum hose from common chamber. 13. Disconnect canister purge hose from common
chamber duct. 14. Remove two bolts securing EGR valve assy to common chamber. Disconnect
Backpressure Transducer (BPT) hose and remove Exhaust Gas
Recirculation (EGR) valve.
15. Remove six bolts, two nuts, and three duct bracket bolts. Remove common chamber duct and
remove duct. 16. Remove fuel feed and return hoses from fuel pipe and two bolts from cylinder
head cover. 17. Disconnect thermo sensor and injector connectors.
19. Remove fuel rail mounting bolts, and remove rail assy complete with injectors.
NOTE:If an injector becomes separated from rail and remains in head, both injector O-ring seals
and retainer clip must be replaced.
Fuel Rail
DISASSEMBLY
1. Remove pressure regulator mounting bolts and remove regulator.
Fuel Injector Retaining Clip Removal

2. Release injector retaining clips and remove injectors.
REASSEMBLY
1. Fuel rail 2. Multiport fuel injection injector assembly
^ Lubricate new injector 0-ring seal with engine oil, and install on injectors.
3. Injector retainer clip 4. Fuel pressure control valve assembly 5. Regulator attaching screw
INSTALLATION
To install, follow the removal steps in the

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Fuel Pressure Regulator: Locations
Fuel Rail
Mounted on fuel rail.

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Fuel Pressure Regulator: Description and Operation
Fuel Pressure Regulator
PURPOSE
It keeps the fuel pressure applied to the injectors between 2.80 - 3.20 kg/cm2 (280 - 320 kPa, 41 -
46 psi) at all times.
OPERATION AND CONSTRUCTION
The fuel pressure regulator is diaphragm-operated relief valve consisting of diaphragm, spring and
valve.
The pressure applied to the chamber "A" of fuel pressure regulator is intake manifold pressure and
that to the chamber "B" is fuel pressure. When the fuel pressure rises more than a predetermined
level higher than the intake manifold pressure, the fuel pushes the valve in the regulator open and
excess fuel returns to the fuel tank via the return line.
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Locations

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
PURPOSE
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Locations
Component Locations

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Locations > Page 2088
PURPOSE
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Fuse Panel

Fuel Pump Circuit
PURPOSE
LOCATION

OPERATION
fuel pump.
Fuel Pump Circuit

Circuit Description
Test Description
Diagnostic Aids
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Locations
Fuel Rail: Locations
Fuel Rail
Located on top of engine mounted to the Inlet manifold.

> Locations > Page 2098
Fuel Rail: Description and Operation
Fuel Rail Assembly
PURPOSE
The fuel rail assembly performs several functions: It positions the injectors in the cylinder head, it
distributes fuel evenly to the injectors, and it integrates the fuel pressure control valve into the fuel
metering system.
CONSTRUCTION
The fuel rail is a metal tube with threaded fittings, that forms a connection between the fuel
supply/return hoses, the Fuel Pressure Regulator and the Fuel Injectors
Fuel Rail: Service and Repair
Before starting disconnect battery ground cable.
Fuel Injector Rail
REMOVAL
1. Remove air cleaner assy. 2. Disconnect accelerator cable from throttle body and cable brackets
and remove cable. 3. Disconnect canister vacuum hose from Vacuum Switching Valve (VSV). 4.
Disconnect Air vacuum hose from common chamber.. 5. Disconnect vacuum booster hose from
common chamber duct. 6. Disconnect Connectors from Manifold Absolute Pressure sensor,
canister Vacuum Switching Valve (VSV), Exhaust Gas Recirculation VSV,
Intake Air Temperature and ground cable.
7. Remove spark plug wires from cylinder heads. 8. Disconnect three connectors from Ignition
Control Module assembly, Remove three Electronic Ignition bracket fixing bolts, and remove
Electronic Ignition assembly with plug wires.
9. Remove four bolts from throttle valve housing and remove housing. 10. Disconnect EVAP
canister and Exhaust Gas Recirculation VSV hoses from throttle body. 11. Disconnect Positive
Crankcase Ventilation (PCV) hose from common chamber duct. 12. Disconnect fuel pressure
control vacuum hose from common chamber. 13. Disconnect canister purge hose from common
chamber duct. 14. Remove two bolts securing EGR valve assy to common chamber. Disconnect
Backpressure Transducer (BPT) hose and remove Exhaust Gas
Recirculation (EGR) valve.
15. Remove six bolts, two nuts, and three duct bracket bolts. Remove common chamber duct and
remove duct. 16. Remove fuel feed and return hoses from fuel pipe and two bolts from cylinder
head cover. 17. Disconnect thermo sensor and injector connectors.
19. Remove fuel rail mounting bolts, and remove rail assy complete with injectors.
NOTE:If an injector becomes separated from rail and remains in head, both injector O-ring seals
and retainer clip must be replaced.
Fuel Rail
DISASSEMBLY
1. Remove pressure regulator mounting bolts and remove regulator.
Fuel Injector Retaining Clip Removal

2. Release injector retaining clips and remove injectors.
REASSEMBLY
1. Fuel rail 2. Multiport fuel injection injector assembly
^ Lubricate new injector 0-ring seal with engine oil, and install on injectors.
3. Injector retainer clip 4. Fuel pressure control valve assembly 5. Regulator attaching screw
INSTALLATION
To install, follow the removal steps in the

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Fuel Supply Line: Locations
Routed between the fuel tank and engine compartment, under the vehicle.
Fuel Supply Line: Description and Operation
Fuel Diagram
PURPOSE
Provides a sealed path for both fuel and fuel vapor between tank and engine compartment
components.
CONSTRUCTION
Consists of metal tubing, high pressure hose and clamps on fuel delivery circuit and low pressure
hose and clamps on all vapor and fuel return circuits.
Fuel Supply Line: Testing and Inspection
- Visually inspect lines and connections for looseness, kinked or collapsed hoses or other damage.
- Visually inspect fuel tank and filler cap for deformation, cracks or fuel leakage.
- Repair or replace any components found to be damaged or defective.

Fuel Supply Line: Service and Repair
REMOVAL
Preparation: Negative battery cable.
1. Fuel filler cap
WARNING
Be careful to avoid injuring your hand. Use a piece of cloth in case of fuel spillage. 2. Fuel feed
pipe
^ Disconnect the fuel feed pipe from engine side of fuel filter.
3. Fuel feed pipe
^ Disconnect the fuel feed pipe from fuel tank side of fuel filter.
CAUTION:
Cap the ends of the fuel feed pipe and fuel pipe to prevent both entry of dust and spillage.
4. Filter fixing bolt 5. Filter
INSTALLATION
1. Filter
^ Make sure that the fuel filter is installed properly.
2. Filter fixing bolt 3. Fuel feed pipe
^ Connect the fuel feed pipe to fuel tank side of fuel filter.
4. Fuel feed pipe
^ Connect the fuel feed pipe to engine side of fuel filter.
5. Fuel filler cap

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Check and Releif Valve
<--> [Fuel Tank Pressure Release Valve] > Component Information > Locations
Fuel And Vapor System

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Check and Releif Valve
<--> [Fuel Tank Pressure Release Valve] > Component Information > Locations > Page 2114
Check and Releif Valve: Description and Operation
PURPOSE
Controls fuel and vapor flow to the canister.
OPERATION
When vapor pressure in the tank exceeds 5 kPa (1 in.Hg) the valve opens to allow vapor venting to
the canister. When tank pressure is below the specified value, the valve closes and vapors are
retained in the tank. The valve prevents vacuum build up in the fuel tank and rollover protection to
prevent liquid fuel from entering the canister during normal driving maneuvers.
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications
Idle Air Control Valve: Specifications
Resistance Value
Between terminals A and B..................................................................................................................

..................................................................40-80 ohms
Between terminals C and D..................................................................................................................

..................................................................40-80 ohms
Idle Air Control Valve: Locations
Throttle Body

Idle Air Control Valve: Description and Operation
IAC Valve
PURPOSE
Allows the Engine Control Module (ECM) control over idle speed.
OPERATION
The Idle Air Control (IAC) Valve is activated by the ECM to control engine idle speed while
preventing stalls due to changes in engine load. The valve is mounted in the intake manifold to
regulate the amount of bypass air around the throttle valve. The ECM sends voltage pulses to IAC
motor windings, causing IAC valve pintle to move in or out a given distance (a step or count) for
each pulse, as needed to obtain the desired idle speed.
During idle, proper IAC valve position is "learned" by the ECM based on battery voltage, coolant
temperature and engine rpm. If the position is incorrect, the ECM will command a reset which will
occur when vehicle speed is about 30 mph.
If rpm drops below a specified value and the throttle is closed, the ECM senses a near stall
condition and will calculate a new valve position to prevent stalling.
Idle Air Control Valve: Testing and Inspection
Chart C-2C IAC System Check

Circuit Description
The engine control module (ECM) controls engine idle speed with idler air control (IAC) valve. To
increase idle speed, the ECM retracts the IAC valve pintle away from its seat, allowing more air to
bypass the throttle bore. To decrease idle speed, it extends the IAC valve pintle towards its seat,
reducing bypass air flow. A "Scan tool" will read the ECM commands to the IAC valve in counts.
Higher counts indicate more air bypass (higher idle). Lower counts indicate less air is allowed to
bypass (lower idle).
Test Description
Number below refer to circled numbers on the diagnostic chart.
1. The IAC tester is used to extend and retract the IAC valve. Valve movement is verified by a
engine speed change. If no change in engine speed occurs, the valve can be retested when
removed from the throttle body.
2. This step checks the quality of the IAC movement in step 1. Between 700 revolution per minute
(rpm) and about 1500 rpm, the engine speed should change smoothly with each flash of the tester
light in both extend and retract. If the IAC valve is retracted beyond the control range (about 1500
rpm), it may take many flashes in the extend position before engine speed will begin to drop. This
is normal on certain engines, fully extending IAC may cause engine stall. This may be normal.
3. Steps 1 and 2 verified proper IAC valve operation. This step checks the IAC circuits. Each lamp
on the node light should flash red and green while the IAC valve is cycled. While the sequence of
color is not important if either light "OFF" or does not flash red and green, check the circuits for
faults, beginning with poor terminal contacts.
Diagnostic Aids
A slow, unstable, or fast idle may be caused by a non-IAC system problem that cannot overcome
by the IAC valve. Out of control range IAC "Scan tool" counts will be above 60 if idle is too low, and
zero counts If Idle is too high. The following checks should be made to repair a non-IAC system
problem.
Vacuum Leak (High Idle) If idle is too high, stop the engine. Fully extend (low) IAC with tester. Start
engine. If idle speed is above 800 rpm, locate and correct vacuum leak including PCV system. Also
check for binding of throttle blade or linkage.
Lean heated oxygen sensor signal (High Air/Fuel Ratio) The idle speed may be too high or too low.
Engine speed may vary up and down and disconnecting the AC valve does not help. Diagnostic
trouble code 44 may be set. "Scan tool" oxygen (02) voltage will be less than 100 mV (.1 volt).
Check for low regulated fuel pressure, water in fuel, or a restricted injector.
Rich heated oxygen sensor signal (Low Air/Fuel Ratio) The idle speed will be too low. "Scan tool"
IAC counts will usually be above 80. System is obviously rich and may exhibit black smoke in
exhaust. "Scan tool" O2 voltage will be fixed about 750 mV (.75 volt). Check for high fuel pressure,
leaking or sticking Injector. Silicon contaminated heated oxygen sensor will "Scan tool" an O2
voltage slow to respond.
Throttle Body Remove IAC valve and inspect bore for foreign material.
IAC Valve Electrical Connections IAC valve connections should be carefully checked for proper
contact.
PCV Valve An incorrect or faulty PCV valve may result in an incorrect idle speed.
If intermittent poor driveability or idle symptoms are resolved by disconnecting the IAC, carefully
recheck connections, valve terminal resistance, or replace IAC.
Idle Air Control Valve: Service and Repair
IDLE AIR CONTROL (IAC) VALVE
REMOVAL
Preparation: ^Battery negative cable.
1. Idle air control (IAC) valve electrical connector 2. IAC valve attaching screw 3. IAC valve
assembly
On IAC valves that have been in service: Do not push or pull on the IAC valve pintle. The force
required to move the pintle may damage the threads on the worm drive. Also, Do not soak the IAC
valve in any liquid cleaner or solvent, as damage may result.
CLEANING AND INSPECTION
^ Clean IAC valve O-ring sealing surface, pintle valve seat and air passage.
- Use carburetor cleaner and a parts cleaning brush to remove carbon deposits. Do Not use a
cleaner that contains methyl ethyl ketone. It is an extremely strong solvent, and not necessary for
this type of deposit.
- Shiny spots on the pintle or seat are normal, and do not indicate misalignment or a bent pintle
shaft.
- If air passage has heavy deposits, remove throttle body for complete cleaning.
^ Inspect IAC valve O-ring for cuts, cracks or distortion. Replace if damaged.
CAUTION: If installing a new IAC valve, be sure to replace it with an identical part. IAC valve pintle
shape and diameter are designed for the specific application.
IAC Valve
INSTALLATION
If installing a new IAC valve, measure the distance from the tip of the IAC pintle to the mounting
flange. If it is greater than 28 mm, use finger pressure to slowly retract the pintle. The force
required to retract the pintle of a "New Valve" will not cause damage to the valve.
1. IAC valve assembly 2. IAC valve attaching screw 3. Idle air control valve electrical connector
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Common Chamber <--> [Intake Air
Plenum] > Component Information > Specifications
Common Chamber: Specifications
Torque .................................................................................................................................................
......................................................... 17 ft lb (24 Nm)
Plenum] > Component Information > Specifications > Page 2126
Common Chamber: Description and Operation
Common Chamber
PURPOSE
Routes intake air from the throttle chamber to the intake manifold.
It is a sealed cast aluminum component with various vacuum fittings and other components
fastened to it.
Common Chamber: Service and Repair
Common Chamber
REMOVE Preparation:
Disconnect battery ground cable
1. Air cleaner assembly
2. Accelerator Pedal cable
^ Disconnect from throttle body and cable bracket.
3. Canister vacuum hose
^ Disconnect from vacuum pipe.
4. Air vacuum hose
^ Disconnect from common chamber.
5. Vacuum booster hose

6. Connectors
^ Disconnect from Manifold Absolute Pressure, canister Vacuum Switching Valve (VSV), Exhaust
Gas Recirculation VSV, Intake Air
Temperature and ground cable.
7. High tension cables
^ Disconnect from cylinder head cover.
8. Ignition Control Module assembly
^ Disconnect three Electronic Ignition connectors. ^ Remove three Electronic Ignition bracket fixing
bolts, and remove Electronic Ignition assembly with plug wires.
9. Throttle body
^ Remove four fixing bolts.
10. Vacuum hoses
^ Disconnect vacuum hoses on canister VSV and Exhaust Gas Recirculation VSV from the Throttle
Body.
11. Positive crankcase ventilation hose
12. Fuel Pressure Control Valve vacuum hose
13. Evaporative Emission Canister Purge hose
14. Exhaust Gas Recirculation Valve assembly
^ Remove two bolts on common chamber to disconnect Backpressure Transducer vacuum hose.
15. Common chamber

^ Remove six bolts and two nuts and three bracket fixing bolts. ^ Remove the common chamber.
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Fuse Panel

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 2132
PURPOSE
OPERATION
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuse Panel

Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2137
Fuel Pump Circuit
PURPOSE
LOCATION

OPERATION
fuel pump.
Fuel Pump Circuit

Circuit Description
Test Description
Diagnostic Aids
Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Fuse Panel

Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2143
PURPOSE
OPERATION
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Rollover Valve: Locations
Fuel And Vapor System
LOCATION
On top of the fuel tank, at the evaporation fitting.

Rollover Valve: Description and Operation
Rollover And Float Valve
PURPOSE
Prevents fuel from flowing into the canister and leaking in the event of vehicle rollover.
OPERATION
When the vehicle rolls over, the float in the valve closes off the evaporation passage.
Rollover Valve: Testing and Inspection
Rollover And Float Valve
Check rollover and float valve for fuel leaks, distortion, cracks, dents and orifice clogging. Replace
if found defective.
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications

At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications >
Page 2154
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2155

TPS
PURPOSE
OPERATION
is set.

TP Sensor
TP sensor
INSTALL OR CONNECT

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Throttle Body: Specifications
Torque .................................................................................................................................................
......................................................... 16 ft lb (22 Nm)
Throttle Body: Locations
LOCATION
On the intake common chamber.

Throttle Body: Description and Operation
Throttle Body
PURPOSE
Provides a means to controlling air flow into the engine, thereby controlling engine operation.
CONSTRUCTION
The throttle body consists of the main bore, air bypass passage, vacuum passage for vacuum
operated components and the following parts. -
Throttle valve which is interlocked with the accelerator pedal and controls the amount of the intake
air
- Throttle Position Sensor (TPS) which detects the throttle valve opening and sends a signal to
Engine Control Module (ECM)
- Idle air control valve which controls the amount of air bypassing the throttle valve during idle.
The last three digits of the eight digit identification number are stamped on the TB casting, next to
the throttle stop screw. The part number begins with "17091..." Refer to this number if servicing or
part replacement is required.
Information > Service and Repair > Removal and Replacement
Throttle Body: Service and Repair Removal and Replacement
Throttle Body
REMOVAL AND INSTALLATION
Remove as outlined in image. Reverse steps to refit. Torque throttle body mounting bolts to: 16 ft lb
(22 Nm)
Information > Service and Repair > Removal and Replacement > Page 2167
Throttle Body: Service and Repair Cleaning
CLEANING
NOTE: The Throttle Position Sensor and Idle Air Control valve should NOT come in contact with
solvent or cleaner, as they may be damaged.
Be careful when cleaning old gasket material from machined aluminum surfaces. Be sure all
sealing surfaces are clean.
The throttle bore and valve deposits may be cleaned on-vehicle, using carburetor cleaner and a
shop towel. Do not use a cleaner that contains methyl ethyl ketone. It is an extremely strong
solvent, and not necessary for this type of deposit.
The Throttle Body (TB) metal parts may be cleaned following disassembly, in a cold
immersion-type cleaner.
Information > Service and Repair > Removal and Replacement > Page 2168
Throttle Body: Service and Repair Minimum Throttle Body Position Check
The minimum throttle body (TB) position (throttle stop Screw) adjustment for the 3.2L should not be
considered the "minimum idle speed", as on other fuel injected engines. Low internal friction and
provision for slight production variations and various operation altitudes resulted in a calibrated
minimum TB position which is too low to allow most engines to idle. The adjustment is preset at the
factory and no further adjustment should be necessary.
If there is a complaint of high idle speed, vacuum leaks should be considered the most likely cause.
Because the Engine Control Module (ECM) "learns" idle IAC, it is even less likely that a stalling
complaint would be due to an incorrect minimum TB position. In either case, the "Symptoms"
Section and IAC valve check CHART C-2C should be referred to. See: Computers and Control
Systems/Testing and Inspection/Component Tests and General Diagnostics/Lettered Diagnostic
Charts/C - Charts/C-2C ~ Idle Air Control System (IAC)
If it is determined that the minimum TB position is suspect, be sure IAC valve is not "lost" (not
actually at the location indicated by current IAC "counts"). The IAC valve could be "lost" if ECM
power has been interrupted with the ignition "ON", or the IAC valve has been disconnected with the
engine running since last reset, as described previously in this section in the IAC Valve Assembly"
general description.
Minimum Throttle Body (TB) Position
CAUTION
It is extremely unlikely that this adjustment will ever be necessary on a TB that has not been
tampered with after production. If idle revolution per minute is low, you may need to replace the TB
to correct the low idle speed.
The minimum TB position may be checked using the following procedure.
1. Block drive wheels, and apply parking brake. 2. connect Scan tool" to the data link connector. 3.
start engine and allow to reach operating temperature (about 90°C) and Closed Loop. 4. shift to
DRIVE ("D") and then back to neutral
5. Select power steering pressure switch input on "Scan Tool". With air conditioning and all
electrical accessories "OFF", transmission in natural,
"Scan tool" should read "OFF" or "NORMAL. (If not, refer to CHART C-1 E to diagnose and repair
faulty power steering pressure switch circuit before proceeding). Allow idle to stabilize.
6. Select IAC valve display on "Scantool" and read IAC valve Counts. If between 5-45 counts, the
minimum TB position adjustment is acceptable. It
is important to allow idle speed to stabilize to assure correct counts are determined. If counts in
step 6 are too low, check for if intake (vacuum) leaks at hoses, TB and intake manifold or damaged
throttle lever and correct as necessary. Also, refer to CHART C-2C "Diagnostic Aids. See:
Computers and Control Systems/Testing and Inspection/Component Tests and General
Diagnostics/Lettered Diagnostic Charts/C - Charts/C-2C ~ Idle Air Control System (IAC)
If no vacuum leaks or other cause of excessive air into the intake are found, it may be necessary to
replace the TB to correct the low idle speed problem.
If counts in step 6 are too high, check for damaged throttle lever or airflow restriction by the TB. If
problem is evident, remove inlet air duct at the TB and clean residue from inside of TB bore and
edges of TB using carburetor cleaner and a shop towel. Do Not use a cleaner that contains Methyl
ethyl ketone. It is an extremely strong solvent, and not necessary for this type of deposit. Re-check
"Scan tool" IAC valve counts, per the preceding procedure. If counts are still too high it may be
necessary to replace the IAC valve or the TB assembly, If no vacuum leaks are indicated or engine
loads are present
Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Accelerator Cable Adjustment

Component Information > Testing and Inspection > With Cruise Control
Throttle Cable/Linkage: Testing and Inspection With Cruise Control
Accelerator Cable And Pedal
- Check throttle cable and accelerator pedal for smooth operation. - Be sure cable is routed
properly with no sharp bends or kinks. - Check for frayed cable at both ends. Replace cable if
frayed, kinked, or sticking.
Component Information > Testing and Inspection > With Cruise Control > Page 2174
Throttle Cable/Linkage: Testing and Inspection W/O Cruise Control
Accelerator Cable
- Check throttle cable and accelerator pedal for smooth operation. - Be sure cable is routed
properly with no sharp bends or kinks. - Check for frayed cable at both ends. Replace cable if
frayed, kinked, or sticking.
Component Information > Testing and Inspection > Page 2175
Throttle Cable/Linkage: Adjustments
Accelerator Cable Adjustment
1. Loosen adjusting nut.
2. Lock throttle valve fully closed and pull outer cable.
3. Adjust nut "B" so that clearance is as shown.
4. Push nut "B" against bracket and tighten nut "A" to lock cable.
Component Information > Service and Repair > With Cruise Control
Throttle Cable/Linkage: Service and Repair With Cruise Control
Accelerator Cable And Pedal
Removal steps
1. Auto cruise control cable 2. Accelerator Pedal control cable 3. Accelerator Pedal assembly
Installation steps

Component Information > Service and Repair > With Cruise Control > Page 2178
Throttle Cable/Linkage: Service and Repair W/O Cruise Control
Accelerator Cable Replacement
Removal steps
1. Adjusting clip. 2. Cable clip. 3. Accelerator control cable (Throttle valve side). 4. Accelerator
control cable (Accelerator pedal side). 5. Grommet 6. Accelerator control cable
Installation steps

Isuzu Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >

At idle ...................................................................................................................................................
........................................................... less than .85V At WOT ............................................................
................................................................................................................................................ approx.
4.5V
Torque: ................................................................................................................................................
............................................. 2 N.m (18 lb.in)

TPS
PURPOSE
OPERATION
is set.

TP Sensor
TP sensor
INSTALL OR CONNECT

Isuzu Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Isuzu Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Firing Order: 1 - 2 - 3 - 4 - 5 - 6
Isuzu Workshop Manuals > Powertrain Management > Ignition System > Electronic Ignition Assembly <--> [Ignition Coil
Pack] > Component Information > Specifications
Electronic Ignition Assembly: Specifications
Torque .................................................................................................................................................
......................................................... 16 ft lb (22 Nm)
Pack] > Component Information > Specifications > Page 2200
Electronic Ignition Assembly: Description and Operation
PURPOSE
Provides high voltage necessary to ignite the combustion gas.
OPERATION
The electronic ignition system uses a waste spark method of distribution. For example, in this type
of system the ignition control module triggers the #1-4 coil pair resulting in both #1 and #4 spark
plugs firing at the same time #1 cylinder is on the compression stroke at the same time #4 is on the
exhaust stroke, resulting in a lower energy requirement to fire #4 spark plug. This leaves the
remainder of the high voltage to be used to fire #1 spark plug.
Electronic Ignition Assembly: Service and Repair
2. Disconnect spark plug wires from Electronic Ignition (EI) assembly.
3. Disconnect connectors on Engine Control Module (ECM), power supply, and Crankshaft Position
Sensor (CKP).
4. Remove three bolts securing EI unit and remove unit.
5. Reverse steps to refit. Be sure to fit spark plug wires to correct terminals. Tighten mounting bolts
to lb-ft (Nm) 19 (25)
Isuzu Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
87 in lb (10 Nm)

PURPOSE
engine speed.
REMOVE

Protection Shield
REFIT
87 in lb (10 Nm)
46 ft lb (63 Nm)
27 ft lb (37 Nm)

Isuzu Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 > Spark Plug
Tube - Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > SB96-01-L005 > Sep > 96 > Spark Plug
Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Technical Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Technical Service Bulletins > All Other Service Bulletins for Ignition Cable: > SB97-01-L003 > Jun > 97 > Spark Plug Tube -
Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
No.1 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.2 .....................................................................................................................................................
................................................ 5.7 - 13.1 K Ohms
No.3 .....................................................................................................................................................
................................................ 6.2 - 14.4 K Ohms
No.4 .....................................................................................................................................................
................................................ 5.8 - 13.3 K Ohms
No.5 .....................................................................................................................................................
................................................ 6.4 - 14.9 K Ohms
No.6 .....................................................................................................................................................
................................................ 6.9 - 16.0 K Ohms
Ignition Wire
PURPOSE
CONSTRUCTION
Cable # ................................................................................................................................................
.............................................................. x 1000 ohms
1 ...........................................................................................................................................................
................................................................... 6.4 - 14.9 2 ......................................................................
........................................................................................................................................................ 5.7
- 13.1 3 ................................................................................................................................................
.............................................................................. 6.2 - 14.4 4 ...........................................................
..............................................................................................................................................................
..... 5.8 - 13.3 5 ....................................................................................................................................
.......................................................................................... 6.4 - 14.9 6 ...............................................
..............................................................................................................................................................
................. 6.9 - 16.0
Remove wires.

Isuzu Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation
Ignition Coil: Description and Operation
PURPOSE
Transforms battery voltage into ignition voltage and delivers it in the form of a high voltage surge to
the secondary ignition components.
CONSTRUCTION
The ignition coil contains two sets of copper wire windings around a soft iron core. The primary
winding is made of a hundred or so turns of a heavy gage wire. It is connected to the battery
through the ignition relay. The secondary winding contains several thousand turns of wire wound
directly onto the iron core. The ratio of the number of wraps in the secondary winding to the
number of wraps in the primary windings determines the output voltage of the coil. The secondary
winding is connected to the coil output tower through the iron core.
OPERATION
When current flow in the primary winding is stopped (by the ignitor), the collapse of the magnetic
field causes a voltage to be induced in the secondary windings. Voltage flows out of the coil's
secondary terminal, through the ignition cable, into the spark plug and jumps the electrode gap to
ground causing a spark.
Isuzu Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Page 2239
Ignition Coil: Service and Repair
REMOVE
1. Coil retaining screws (2 each coil) 2. Coil(s) from module.
REFIT
1. Coil(s) to module. 2. Coil retaining screws

Isuzu Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information
> Locations
Coil Pack

REFIT
Isuzu Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Locations
Coil Pack

Control Module > Component Information > Locations > Page 2249
Control Module > Component Information > Locations > Page 2250
REFIT
Isuzu Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications
87 in lb (10 Nm)
Crankshaft Position Sensor > Component Information > Specifications > Page 2255

PURPOSE
engine speed.
REMOVE

Protection Shield
REFIT
87 in lb (10 Nm)
46 ft lb (63 Nm)
27 ft lb (37 Nm)

Isuzu Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil
Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube -
Replacement Procedure
GROUP: ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
Replacement Procedure > Page 2270

Replacement Procedure > Page 2271
Service Bulletins > All Technical Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube -
Replacement
GROUP ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
(2.56 in. +/- .02 in).

Service Bulletins > Customer Interest: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Service Bulletins > All Other Service Bulletins for Spark Plug: > SB96-01-L004 > Apr > 96 > Spark Plug Tube - Replacement
Procedure
GROUP: ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
Procedure > Page 2288

Procedure > Page 2289
Service Bulletins > All Other Service Bulletins for Spark Plug: > SB9501L002 > Aug > 95 > Spark Plug Tube - Replacement
GROUP ENGINE
APPLICABLE VEHICLES
SERVICE INFORMATION
DISASSEMBLY
1. Spark Plug Tube
CLEAN
REASSEMBLY
1. Spark Plug Tube
> Page 2294
> Page 2295
(2.56 in. +/- .02 in).

Isuzu Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Electrical Specifications

..................................................... 50 Mohms or more
Specifications > Electrical Specifications > Page 2298
Spark plug gap ....................................................................................................................................

.................................. 0.040 - 0.043 in (1.0 - 1.1 mm)

......................................................... 13 ft lb (18 Nm)

PURPOSE
HEAT RANGE
plug to be hotter.
occur.
INSPECTION
RESISTANCE
50 M ohms
1.05 mm (0.040 in)
SOOTY SPARK PLUGS
Rich fuel mixture.
Lean fuel mixture.

Isuzu Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids -
Transmission and Drivetrain > Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information
> Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T - Clunking
Noise on 3-2 Downshift
Band Control Solenoid Valve: Customer Interest A/T - Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
> Technical Service Bulletins > All Technical Service Bulletins for Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T
- Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Pressure Regulating Solenoid: Specifications
RESISTANCE
Between TCM connector terminals 40 and 41

....................................................................................................................................... below 7
ohms
Pressure Regulating Solenoid: Locations
In adapter case valve body, accessed by removing adapter case pan.
Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing
and Inspection
Shift Interlock Solenoid: Testing and Inspection
The shift lock solenoid prevents the gear selector from being moved to any gear, unless the brake
is applied. No adjustments are required. Replace if not functioning properly, refer to Fig. 2 for
terminal locations.
1. Connect 12V battery positive, to terminal No.1. 2. Connect battery ground to Terminal No. 2. 3. If
the solenoid is not functioning properly, replace as necessary.
Isuzu Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators -
Transmission and Drivetrain > Lamps and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information >
CIRCUIT DESCRIPTION
CIRCUIT DESCRIPTION
257°F (125°C).
CIRCUIT DIAGRAM


Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and
Operation
Shift Indicator: Description and Operation
Shift Light Circuit
PURPOSE
Informs the driver to shift to the next higher gear, to improve economy.
LOCATION
OPERATION
The light is conyrolled by the Engine Control Module (ECM) and is turned "ON" by grounding the
ORN/BLU wire. The ECM uses information from the following inputs to control the shift light.
The ECM uses information from the following inputs to control the shift light: ^
Engine coolant temperature sensor
^ Throttle position sensor
^ Vehicle speed sensor
^ Revolution per minute
The ECM uses the measured revolution per minute and the vehicle speed to calculate what gear
the vehicle is in. It's this calculation that determines when the shift light should be turned "ON".
Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Transmission Mode Indicator - A/T: Description and Operation
Lamp lights to inform the driver when transmission is operating in power mode.
Isuzu Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules -
Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > A/T - (4L30E) Control Module Identification
GROUP TRANSMISSION

CHART
AFFECTED VEHICLES
SERVICE INFORMATION

Service Bulletins > A/T - (4L30E) Control Module Identification > Page 2343
column.
CODE column.
NUMBER column.


PURPOSE
conditions.
OPERATION
shifting.
malfunction.
Isuzu Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches -
Transmission and Drivetrain > Sensors and Switches - A/T > Barometric Pressure Sensor, A/T > Component Information >
Locations
Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Locations

Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
PURPOSE
OPERATION
Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
APPROX. RESISTANCE
@ -40°F (-40°C) ..................................................................................................................................

..................................................... 672 K ohms @ 32°F (0°C) .............................................................
................................................................................................................................. 65 K ohms @
68°F (20°C) .........................................................................................................................................
................................................... 25 K ohms @ 176°F (80°C) .............................................................
............................................................................................................................ 2.5 K ohms @
248°F (120°C) .....................................................................................................................................
..................................................... 780 ohms @ 302°F (150°C) ..........................................................
................................................................................................................................ 370 ohms
Isuzu Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T - Clunking Noise on 3-2
Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
Actuators and Solenoids - A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T - Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications
RESISTANCE

....................................................................................................................................... below 7
ohms
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > Page 2383

Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection
terminal locations.
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids -
A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T - Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
A/T > Band Control Solenoid Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T - Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications
RESISTANCE

....................................................................................................................................... below 7
ohms
A/T > Pressure Regulating Solenoid, A/T > Component Information > Specifications > Page 2405

A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection
terminal locations.
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Control Solenoid
Valve, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Control
Solenoid Valve: > 9305014 > Jul > 93 > A/T - Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Control Solenoid
Valve, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: >
9305014 > Jul > 93 > A/T - Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Barometric Pressure
Sensor, A/T > Component Information > Locations

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Service and Repair
Case: Service and Repair
Information > Service and Repair > Page 2428
CASE AND ASSOCIATED PARTS

INTERNAL PARTS
CENTER SUPPORT
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > SB9305022 > Dec > 93 > A/T -
4L30E Rattle From Gear Selector Area
Clutch: All Technical Service Bulletins A/T - 4L30E Rattle From Gear Selector Area
GROUP TRANSMISSION
4L30-E A/T REVERSE CLUTCH PLATE RATE
AFFECTED VEHICLES
1990-91 Trooper II (KT), 1991-93 Rodeo (UC) and 1992-93 Trooper (UX) models equipped with
4L30-E automatic transmission before A/T serial No. 4207367.
NOTE
The A/T serial number is stamped on the identification plate located on the left side of the
transmission case, above the mode switch (Figure 1)
SERVICE INFORMATION
On some affected vehicles, when driving at engine speeds 2000-3000 rpm with light throttle, a
rattling noise may be heard from the gear selector lever area. The noise may be caused by the A/T
reverse clutch plates rattling against the main transmission case.
To eliminate the noise, install the new, improved reverse clutch plates listed in the "Parts
Information" section of this Service Bulletin.
SERVICE PROCEDURE
1. Confirm source of rattling noise by test driving vehicle as follows:
a. Start the engine and allow to idle until it reaches normal operating temperature.
b. Drive at engine speeds between 1000-3000 rpm in each forward gear. If the noise is caused by
reverse clutch plates, an irregular rattling noise will be heard at about 2000 rpm when applying light
throttle.
c. With the vehicle raised on a hoist, listen for a rattling noise about 1" to 2" behind the front cooler
line while running engine at 2000 rpm in any forward gear.
4L30E Rattle From Gear Selector Area > Page 2439
2. If it is confirmed that the noise is caused by reverse clutch plates rattling, replace the reverse
clutch plate pack and seals (Figure 2) as described in the appropriate Workshop Manual, using
new, improved parts in the Reverse Clutch Plate Pack and Seal Kit listed in the "Parts Information"
section of this Service Bulletin. Follow the instructions provided with the kit.
3. During transmission reassembly, also replace the main case 0-rings (Figure 3), listed in "Parts
Information" section.
4. Retest the vehicle as described in Step 1, to ensure the rattle is eliminated.
PARTS INFORMATION

4L30E Rattle From Gear Selector Area > Page 2440

Information > Technical Service Bulletins > Customer Interest for Clutch: > SB9305022 > Dec > 93 > A/T - 4L30E Rattle
From Gear Selector Area
Clutch: Customer Interest A/T - 4L30E Rattle From Gear Selector Area
GROUP TRANSMISSION
4L30-E A/T REVERSE CLUTCH PLATE RATE
AFFECTED VEHICLES
1990-91 Trooper II (KT), 1991-93 Rodeo (UC) and 1992-93 Trooper (UX) models equipped with
4L30-E automatic transmission before A/T serial No. 4207367.
NOTE
The A/T serial number is stamped on the identification plate located on the left side of the
transmission case, above the mode switch (Figure 1)
SERVICE INFORMATION
On some affected vehicles, when driving at engine speeds 2000-3000 rpm with light throttle, a
rattling noise may be heard from the gear selector lever area. The noise may be caused by the A/T
reverse clutch plates rattling against the main transmission case.
To eliminate the noise, install the new, improved reverse clutch plates listed in the "Parts
Information" section of this Service Bulletin.
SERVICE PROCEDURE
1. Confirm source of rattling noise by test driving vehicle as follows:
a. Start the engine and allow to idle until it reaches normal operating temperature.
b. Drive at engine speeds between 1000-3000 rpm in each forward gear. If the noise is caused by
reverse clutch plates, an irregular rattling noise will be heard at about 2000 rpm when applying light
throttle.
c. With the vehicle raised on a hoist, listen for a rattling noise about 1" to 2" behind the front cooler
line while running engine at 2000 rpm in any forward gear.
From Gear Selector Area > Page 2446
2. If it is confirmed that the noise is caused by reverse clutch plates rattling, replace the reverse
clutch plate pack and seals (Figure 2) as described in the appropriate Workshop Manual, using
new, improved parts in the Reverse Clutch Plate Pack and Seal Kit listed in the "Parts Information"
section of this Service Bulletin. Follow the instructions provided with the kit.
3. During transmission reassembly, also replace the main case 0-rings (Figure 3), listed in "Parts
Information" section.
4. Retest the vehicle as described in Step 1, to ensure the rattle is eliminated.
PARTS INFORMATION

From Gear Selector Area > Page 2447

Information > Service and Repair > Third Clutch and Sprag Unit
Clutch: Service and Repair Third Clutch and Sprag Unit
THIRD CLUTCH AND SPRAG UNIT
DISASSEMBLY 1. Retaining ring (Fig. 7A-69)
^ Place the third clutch housing and intermediate shaft assembly upright, using the overdrive
internal gear as a support.
^ Locate the end of the sprag retaining ring. Compress near the end, using a screwdriver through
the side slot and slide one tool blade between ring and drum to hold the ring clear of the groove.
^ Repeat with a second tool blade near the other end of the retaining ring.
^ Repeat with a third tool blade opposite the first two.
^ Repeat with two further blades equally spaced apart. Third clutch retaining ring compressor:
J-38450
2. Input sun gear assembly
^ Pull the input sun gear assembly unit until the sprag retaining ring clears the ring groove.
3. Retaining washer 4. Bearing 5. Thrust washer 6. Clutch plates 7. Third clutch drum
Visual check
^ If any damage, deformation or local wear is found in a bearing, thrust washer, clutch plates or
third clutch drum, replace it.
Information > Service and Repair > Third Clutch and Sprag Unit > Page 2450
REASSEMBLY
7. Third clutch drum 6. Clutch plates
^ Place third clutch housing and intermediate shaft assembly upright, using the overdrive internal
gear as a support.
^ Install third clutch spring cushion plate, bevel face down.
^ Install third clutch plates into clutch housing. Start with the steel clutch plate and alternate with
lined plates.
5. Thrust washer 4. Bearing 3. Retaining washer
2. Input sun gear assembly (Fig. 7A-70) 1. Retaining ring
^ Fully engage the sprag assembly hub splines into the third clutch inner tangs. Simultaneously
rotate the outer sprag race to engage into the third clutch housing.
^ Install a tool blade at each extremity of the retaining ring.
^ Compress the retaining ring with a screwdriver opposite the tool blades while pushing down on
the outer sprag race.
^ Engage retaining ring into groove.
^ Remove tool blades
THIRD CLUTCH DISASSEMBLY
1. Retaining ring (Fig. 7A-72)
^ Compress spring seat using the tool.
NOTE: Do not over-stress the springs and seat. This will cause damage to the spring seat. ^
Remove retaining ring.
^ Release the spring seat.
NOTE: Do not let the spring seat catch in the ring groove.
Spring compressor: J-23075

Adapter: J-23075-12
2. Spring seat 3. Springs 4. Piston
Visual check
^ If any damage, deformation or local wear is found in a retaining ring, return spring, piston seals or
spring seat, replace it.
Operation check
^ Shake piston and listen for check ball movement. Replace piston if check ball is missing or falls
out.
REASSEMBLY
4. Piston (Fig. 7A-73)
^ The lip of the seals must point toward the front of the transmission. Lubricate the lip seal with
transmission fluid.
^ Install piston assembly into the third clutch drum. Use installer to protect the outer seal during
installation. Third clutch piston installer: J-23084
3. Springs 2. Spring seat 1. Retaining ring
^ Place retaining ring onto spring seat.
^ Compress the piston springs, using the piston spring compressor.
CAUTION: Do not over-stress the springs and seat. Do not let the spring seat catch in the ring
groove. This may cause damage to the spring seat. ^
Install spring seat retaining ring.

^ Remove the piston spring compressor. Spring compressor: J-23075 Adapter: J-23075-12
SPRAG UNIT
DISASSEMBLY 1. Sprag outer race 2. Sprag assembly
^ Remove sprag outer race and sprag assembly from third clutch hub and sun gear assembly.
3. Sun gear assembly
Visual check
^ If any damage, deformation or local wear is found in a sun gear, sprag assembly or sprag outer
race, replace it.
REASSEMBLY
3. Sun gear assembly 2. Sprag assembly
^ Install sprag assembly onto the sun gear.
NOTE: Flared shoulder of the sprag cage faces the sun gear. This procedure must be followed
exactly to be sure that the sprag assembly is installed properly.
1. Sprag outer race (Fig. 7A-75)
^ Install outer sprag race assembly over the sprag cage assembly.
^ Place third clutch hub and sun gear assembly on a flat surface, sun gear facing up. Place sprag
outer race and sprag assembly over the sun gear assembly, push down and turn the input sun
counterclockwise at the same time.
NOTE: Check correct rotation by holding the sun gear in your left hand and turning the outer race.
The outer sprag race should turn freely towards you and lock turning away from you.
Clutch: Service and Repair Second Clutch
SECOND CLUTCH
Disassembly steps 1. Retaining ring 2. Ring gear 3. Retaining ring 4. Spacer
5. Clutch plates 6. Waved washer 7. Retaining ring (Fig. 7A-77)

^ Compress the spring seat. Compressor: J-23327
8. Spring seat 9. Springs
10. Piston 11. Second clutch drum
Visual check
^ If any damage, deformation or local wear is found in a retaining ring, ring gear, spacer, clutch
plates, piston seals, return spring or spring seat, replace
Operation check
^ Shake piston and listen for check ball movement. Movement indicates proper check ball
operation. Replace piston if check ball is missing or falls out.
REASSEMBLY
11. Second clutch drum
^ Install piston assembly into the second clutch drum. Lubricate the lip seal with liberal amounts of
transmission fluid. Use the installer to protect the outer piston lip seat.
NOTE: Clip of the seals point toward front of transmission. Second clutch piston installer:
J-23080-A
9. Springs 8. Spring seat 7. Retaining ring
^ Install twenty-two piston springs and spring seat on the second clutch piston. Place retaining ring
onto spring seat.
^ Use the compressor to compress the piston springs. Compressor:J-23327

NOTE: Do not let spring seat catch in ring groove.
6. Waved plate 5. Clutch plates
^ Install clutch plates. Start with a steel plate and alternate with lined plates. Align second clutch
inner tangs.
4. Spacer
^ Install spacer, with the fluted end toward clutch plates.
3. Retaining ring 2. Ring gear 1. Retaining ring

Clutch: Service and Repair Accumulator Piston
3-4 ACCUMULATOR PISTON
DISASSEMBLY .
Snap ring (Fig. 7A-80) ^
Install cover compressor on adapter case. Compress piston cover. Remove snap ring.
Compressor: J-38559
2. Cover (Fig. 7A-81)
^ Install cover remover to center hole of cover. Use slide hammer to remove cover. Cover remove
J-38552 Adapter: J-38584 Slide hammer : J-23907
3. Spring 4. Piston
Visual Check
^ If any damage, deformation or wear is found in a return spring, piston or piston cover, replace it
REASSEMBLY
^ Place the fitter into adaptor case and push the piston into position, using suitable diameter tube.
Piston fitter: J-38553
3. Spring 2. Cover (Fig. 7A-83)
^ Install cover, using compressor tool. Compressor: J-38559

1. Snap ring
^ Install snap ring in groove.

Clutch: Service and Repair Reverse Clutch Piston and Center Support
REVERSE CLUTCH PISTON AND CENTER SUPPORT
DISASSEMBLY 1. Retaining ring (Fig. 7A-85)
^ Install the tool on spring seat.
^ Compress the spring seat. Compressor: J-23327
NOTE: Do not over-stress the springs and seat, as this will cause damage to the spring seat.
2. Spring seat 3. Springs 4. Piston 5. Center support
^ Remove 8 bolts from center support. Remove center support from adapter case.
6. Gasket 7. Transfer plate 8. Gasket 9. Restrictor
10. Retainer plate 11. Plug

12. Spring 13. Overrun lock out valve
Visual check
^ If any damage, deformation or local wear is found in a retaining ring, return spring, spring
retainer, piston or center support, replace it.
REASSEMBLY
13. Overrun lock out valve 12. Spring
^ Install overrun lock out valve and spring.
NOTE: Ensure correct assembly of valve. The spring should be located over the long small
diameter end.
11. Plug 10. Pin
9. Restrictor (Fig. 7A-86)
^ Place in the lube overdrive channel in the adapter case housing.
8. Gasket 7. Transfer plate 6. Gasket 5. Center support
^ Install center support with 8 bolts. Torque: N.m (lb.ft) 25 (18)
4. Piston 3. Springs 2. Spring seat 1. Retaining ring
^ Install twenty four springs, spring seat and retaining ring.
^ Install the tool.
^ Compress retaining ring and springs.

^ Seat snap ring in groove. Compressor: J-23327
Clutch: Service and Repair Overrun Clutch and Turbine Shaft
OVERRUN CLUTCH AND TURBINE SHAFT
Disassembly steps 1. Snap ring (Fig. 7A-88)

^ Position overrun clutch assembly upright, using the overdrive internal gear as a support.
^ Remove snap ring.
2. Overdrive carrier assembly 3. Sun gear 4. Turbine shaft 5. Snap ring 6. Backing plate 7. Clutch
plates
8. Snap ring (Fig. 7A-89)
^ Compress piston return spring with compressor. Compressor: J-23327-91
9. Overrun roller clutch cam
10. Roller clutch assembly 11. Overrun clutch release spring retainer 12. Diaphragm spring 13.
Piston 14. Overrun clutch drum 15. Turbine shaft seal rings
Overdrive carrier check (Fig. 7A-90)
^ Check pinion end play with a feeler gage. Clearance mm (in) 0.24-0.64 (0.0094-0.025) If
clearance is outside specified value, replace overdrive carrier assembly.
Visual check
^ If any damage, deformation or local wear is found in a snap ring, diaphragm spring, or spring
retainer, roller clutch assembly, turbine shaft, piston or clutch plates, replace it.
REASSEMBLY
15. Turbine shaft seal rings (Fig. 7A-91)
^ Install seals with grease (petroleum jelly).
14. Overrun clutch drum
13. Piston (Fig. 7A-92, 7A-93)
^ Install the inner installer on the drum.
^ Pre-install piston into outer installer.
^ Install overrun clutch piston assembly. Use the outer installer while pushing piston into drum.
Installer: J-38555
12. Diaphragm spring 11. Overrun clutch release spring retainer 10. Roller clutch assembly
9. Overrun roller clutch cam 8. Snap ring
^ Place snap ring loosely on overrun roller clutch cam.
^ Hold the compressor in a vise. Compress piston return spring with compressor.
^ Set snap ring in ring groove. Compressor: J-23327-91

7. Clutch plates
^ Install clutch plates, start with steel plate and alternate with lined plates.
6. Backing plate 5. Snap ring 4. Turbine shaft 3. Sun gear
^ Overdrive sun gear, countersink pointing downwards.
2. Overdrive carrier assembly
^ Complete overdrive carrier assembly.
NOTE: Turn the assembly in a counter-clockwise direction only until roller clutch enters the outer
race. After assembly, rotate the assembly and listen for loose rollers.
1. Snap ring
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification
GROUP TRANSMISSION

CHART
AFFECTED VEHICLES
SERVICE INFORMATION

Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification > Page 2468
column.
CODE column.
NUMBER column.


PURPOSE
conditions.
OPERATION
shifting.
malfunction.
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T >
Component Information > Technical Service Bulletins > A/T - Diagnostic Connector Location
Data Link Connector, A/T: Technical Service Bulletins A/T - Diagnostic Connector Location
ISSUE DATE March 4, 1993
GROUP TRANSMISSION
RODEO (UC) A/T DIAGNOSTIC CONNECTOR LOCATION (WORKSHOP MANUAL

CORRECTION)
AFFECTED VEHICLES
1993 Rodeo (UC) models equipped with automatic transmission.
SERVICE INFORMATION
The location of the automatic transmission diagnostic (data link) connector is incorrectly shown in
the Workshop Manual:
Component Information > Technical Service Bulletins > A/T - Diagnostic Connector Location > Page 2478
Manual Page No.

1993 Rodeo (UC) Workshop Manual 7A-17
(Publication No. AIMI-SVC-239, part No. 2-90993-072-0)
The A/T diagnostic connector is located behind the driver side kick panel.
This Service Bulletin contains the corrected A/T diagnostic connector location for the referenced
Workshop Manual.
Data Link Connector, A/T: Locations
***UPDATED BY TSB #9305004, MARCH 4, 1993
Correct location is behind driver side kick panel. Location is incorrectly shown in the workshop
manual.
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Locations
Automatic Transmission Dipstick - Dipstick Tube: Locations
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Downshift Switch, A/T >

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Dexron-IIE Fluid - Recommended Usage
Fluid - A/T: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage
GROUP MISCELLANEOUS
AFFECTED VEHICLES
SERVICE INFORMATION

Fluid - A/T: Capacity Specifications
Capacity ...............................................................................................................................................
.......................................... 8.6 Liter (9.1 US quarts)
Fluid - A/T: Fluid Type Specifications
Type .....................................................................................................................................................
.............. DEXRON-II Automatic transmission fluid
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Diagrams
Fluid Pump: Diagrams

Fluid Pump: Service and Repair

CONVERTER HOUSING AND OIL PUMP ASSEMBLY
DISASSEMBLY 1. Converter housing
^ Remove five bolts from converter housing.
2. Outer seal ring 3. Gasket 4. Wear plate 5. Oil pump assembly 6. Oil seal ring
Visual check
^ If any damage, deformation or local wear is found in a converter housing, outer seal ring, wear
plate or oil seal ring, replace it.
OIL PUMP
DISASSEMBLY 1. Oil pump drive gear 2. Oil pump driven gear 3. Pin 4. Plug 5. Spring 6.
Converter clutch control valve 7. Snap ring 8. Spring seat 9. Spring
10. Throttle signal accumulator piston 11. Sleeve pin

12. Sleeve 13. Boost valve 14. Spring seat 15. Valve spring 16. Spring seat 17. Pressure regulator
valve
Visual check
^ If any damage, deformation or local wear is found in a snap ring, spring, spring retainer valve,
gear or oil pump, replace it
REASSEMBLY
17. Pressure regulator valve 16. Spring seat
^ Lubricate and preinstall pressure regulator spring seat on valve, with the flat side against
shoulder.
15. Valve spring 14. Spring seat 13. Boost valve 12. Sleeve 11. Sleeve pin 10. Throttle signal
accumulator piston
9. Spring 8. Spring seat
^ lnstall throttle signal accumulator piston, spring, and spring seat, with the flat side away from the
spring and snap ring.
7. Snap ring 6. Converter clutch control valve 5. Spring 4. Plug 3. Pin 2. Oil pump driven gear 1. Oil
pump drive gear
REASSEMBLY CONVERTER HOUSING

6. Oil seal ring
^ Install oil seal ring using installer. Torque N.m (lb.in) 3 (26)
5. Oil pump assembly 4. Wear plate
^ Install wear plate onto oil pump assembly.
3. Gasket 2. Outer seal ring
1. Converter housing (Fig. 7A-63)
^ Install converter housing onto complete oil pump assembly. Align with two short guide pins on
outer bolt holes.
^ Loosely install five 13 mm bolts
^ Center converter housing using centering tool.
^ Tighten five inner 13 mm bolts in an alternating pattern.

Guide pin: J-38588 Centering tool: J-38557

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Malfunction Indicator Lamp - A/T > Component Information > Description and Operation
CIRCUIT DESCRIPTION
> Malfunction Indicator Lamp - A/T > Component Information > Description and Operation > Page 2503
CIRCUIT DESCRIPTION
257°F (125°C).
CIRCUIT DIAGRAM

> Malfunction Indicator Lamp - A/T > Component Information > Description and Operation > Page 2504

> Shift Indicator > Component Information > Description and Operation
Shift Light Circuit
PURPOSE
LOCATION
OPERATION
> Transmission Mode Indicator - A/T > Component Information > Description and Operation
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Malfunction Indicator Lamp
- A/T > Component Information > Description and Operation
CIRCUIT DESCRIPTION
- A/T > Component Information > Description and Operation > Page 2514
CIRCUIT DESCRIPTION
257°F (125°C).
CIRCUIT DIAGRAM

- A/T > Component Information > Description and Operation > Page 2515

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T >
Overdrive Assembly: Locations
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Specifications
RESISTANCE

....................................................................................................................................... below 7
ohms
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Specifications > Page 2522

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification
GROUP TRANSMISSION

CHART
AFFECTED VEHICLES
SERVICE INFORMATION

Control Module, A/T > Component Information > Technical Service Bulletins > A/T - (4L30E) Control Module Identification >
Page 2528
Page 2529
Page 2530
Page 2531
column.
CODE column.
NUMBER column.

Control Module, A/T > Component Information > Technical Service Bulletins > Page 2532

Control Module, A/T > Component Information > Technical Service Bulletins > Page 2533
PURPOSE
conditions.
OPERATION
shifting.
malfunction.
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Barometric Pressure Sensor, A/T > Component Information > Locations

> Downshift Switch, A/T > Component Information > Locations

> Transmission Mode Switch, A/T > Component Information > Description and Operation
PURPOSE
OPERATION
> Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
APPROX. RESISTANCE
@ -40°F (-40°C) ..................................................................................................................................

..................................................... 672 K ohms @ 32°F (0°C) .............................................................
................................................................................................................................. 65 K ohms @
68°F (20°C) .........................................................................................................................................
................................................... 25 K ohms @ 176°F (80°C) .............................................................
............................................................................................................................ 2.5 K ohms @
248°F (120°C) .....................................................................................................................................
..................................................... 780 ohms @ 302°F (150°C) ..........................................................
................................................................................................................................ 370 ohms
> Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 2547

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Testing and Inspection
terminal locations.
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Adjustments
Shifter A/T: Adjustments
1. Place the selector lever in Neutral range. 2. Install mode switch, then align slot in support with
slot in back. 3. Insert 0.09 inch diameter pin into both ports. 4. Torque mounting bolts to 9 ft. lbs.,
then remove tool.
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: >
SB96-04-L004 > Jun > 96 > Speedometer - Inoperative
Speedometer Gear, A/T: All Technical Service Bulletins Speedometer - Inoperative
GROUP: ELECTRICAL
1991-96 RODEO (UC) SPEEDOMETER INOPERATIVE
AFFECTED VEHICLES
1991-96 Rodeo (UC) 4 X 2 models equipped with 4L30-E automatic transmission.
SERVICE INFORMATION
On some affected vehicles, the speedometer may become inoperative. This speedometer failure
may be caused by premature wear of the speedometer driven gear teeth.
To correct the problem, remove the speedometer driven gear bushing and inspect the gear teeth
for wear. If wear is evident, replace the original speedometer driven gear with a new, improved
speedometer driven gear (Part No. 8-97144-659-0) using the procedure described in this Service
Bulletin. If gear wear is not evident, examine and service speedometer components in accordance
with the appropriate Workshop Manual.
SERVICE PROCEDURE
REMOVAL
Vehicle Speed Sensor/Speedometer Driven Gear Bushing
^ Remove wiring harness connector from vehicle speed sensor.
^ Remove 6 mm retaining bolt on extension housing.
^ Remove speedometer driven gear bushing and 0-ring from extension housing.
INSPECTION
Speedometer Driven Gear
^ Inspect gear teeth for wear.
^ If any gear teeth are less than 0.5 mm in width, replace original speedometer driven gear with
new speedometer driven gear (Part No. 8-97144-659-0) using installation procedure below.
^ If all gear teeth have a width of greater than 0.5 mm, examine and service speedometer
components in accordance with appropriate Workshop Manual.
INSTALLATION
1. Speedometer Driven Gear

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Gear, A/T: >
SB96-04-L004 > Jun > 96 > Speedometer - Inoperative > Page 2563
^ Install new speedometer driven gear into speedometer driven gear bushing (Figure 1).
2. Vehicle Speed Sensor/Speedometer Driven Gear Bushing
^ Install 0-ring an speedometer driven gear bushing into extension housing.
^ Install 6 mm retaining bolt onto extension housing. Torque bolt to 7 Nm (60 in. lbs).
^ Install wiring harness connector onto vehicle speed sensor.
PARTS INFORMATION
8-97144-659-0 Driven Gear; Speedometer 1
Use the following published labor operation:

Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear, A/T: > SB96-04-L004 >
Jun > 96 > Speedometer - Inoperative
Speedometer Gear, A/T: Customer Interest Speedometer - Inoperative
GROUP: ELECTRICAL
1991-96 RODEO (UC) SPEEDOMETER INOPERATIVE
AFFECTED VEHICLES
1991-96 Rodeo (UC) 4 X 2 models equipped with 4L30-E automatic transmission.
SERVICE INFORMATION
On some affected vehicles, the speedometer may become inoperative. This speedometer failure
may be caused by premature wear of the speedometer driven gear teeth.
To correct the problem, remove the speedometer driven gear bushing and inspect the gear teeth
for wear. If wear is evident, replace the original speedometer driven gear with a new, improved
speedometer driven gear (Part No. 8-97144-659-0) using the procedure described in this Service
Bulletin. If gear wear is not evident, examine and service speedometer components in accordance
with the appropriate Workshop Manual.
SERVICE PROCEDURE
REMOVAL
Vehicle Speed Sensor/Speedometer Driven Gear Bushing
^ Remove wiring harness connector from vehicle speed sensor.
^ Remove 6 mm retaining bolt on extension housing.
^ Remove speedometer driven gear bushing and 0-ring from extension housing.
INSPECTION
Speedometer Driven Gear
^ Inspect gear teeth for wear.
^ If any gear teeth are less than 0.5 mm in width, replace original speedometer driven gear with
new speedometer driven gear (Part No. 8-97144-659-0) using installation procedure below.
^ If all gear teeth have a width of greater than 0.5 mm, examine and service speedometer
components in accordance with appropriate Workshop Manual.
INSTALLATION
1. Speedometer Driven Gear

Component Information > Technical Service Bulletins > Customer Interest for Speedometer Gear, A/T: > SB96-04-L004 >
Jun > 96 > Speedometer - Inoperative > Page 2569
^ Install new speedometer driven gear into speedometer driven gear bushing (Figure 1).
2. Vehicle Speed Sensor/Speedometer Driven Gear Bushing
^ Install 0-ring an speedometer driven gear bushing into extension housing.
^ Install 6 mm retaining bolt onto extension housing. Torque bolt to 7 Nm (60 in. lbs).
^ Install wiring harness connector onto vehicle speed sensor.
PARTS INFORMATION
8-97144-659-0 Driven Gear; Speedometer 1
Use the following published labor operation:

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Indicator - A/T > Component Information > Description and Operation
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation
PURPOSE
OPERATION
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Specifications
APPROX. RESISTANCE
@ -40°F (-40°C) ..................................................................................................................................

..................................................... 672 K ohms @ 32°F (0°C) .............................................................
................................................................................................................................. 65 K ohms @
68°F (20°C) .........................................................................................................................................
................................................... 25 K ohms @ 176°F (80°C) .............................................................
............................................................................................................................ 2.5 K ohms @
248°F (120°C) .....................................................................................................................................
..................................................... 780 ohms @ 302°F (150°C) ..........................................................
................................................................................................................................ 370 ohms
Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Specifications > Page 2579

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Turbine Shaft, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turbine Shaft: > SB96-05-L002 >
Jul > 96 > A/T - (4L30E) Delayed Gear Engagement
Turbine Shaft: All Technical Service Bulletins A/T - (4L30E) Delayed Gear Engagement
ISSUE DATE: JULY 1996
GROUP: TRANSMISSION
TROOPER (UX) AND RODEO (UC) 4L30-E AUTOMATIC TRANSMISSION DELAYED GEAR
ENGAGEMENT
AFFECTED VEHICLES
All Trooper (UX) and Rodeo (UC) models equipped with 4L30-E automatic transmission.
SERVICE INFORMATION
Some affected vehicles may experience a noticeable delay from the time that gear selection is
made to the time that gear engagement occurs. This usually occurs after the vehicle has been
parked for an extended period of time (e.g., overnight) and only on the initial gear engagement
when shifting into drive or reverse. This delay may be caused by torque converter draindown.
This condition does not affect transmission operation, once the torque converter refills, and is not
harmful to the transmission. However, if it is necessary to eliminate this condition, replace the scarf
cut seal ring located on the first groove of the turbine shaft with a solid seal ring, using a Turbine
Shaft Seal Kit (Part No. 8-96041-327-0), in accordance with the procedure in this Service Bulletin.
NOTE
A short delay (i.e., 3 seconds or less) is normal when first engaging drive or reverse after allowing
the vehicle to sit overnight.
SERVICE PROCEDURE
DISASSEMBLY
Transmission Assembly ^
Disassemble in accordance with Section 7A of appropriate Workshop Manual, to allow access to

turbine shaft seal rings.
REMOVAL
Scarf Cut Seal Ring

Jul > 96 > A/T - (4L30E) Delayed Gear Engagement > Page 2588
^ Remove scarf cut seal ring located in first groove of turbine shaft (Figure 1).
NOTE
The first groove is the groove closest to the torque converter.
INSTALLATION
Solid Seal Ring ^
Lubricate first groove of turbine shaft and solid seal ring (from Turbine Shaft Seat Kit) with
petroleum jelly.
^ Slip solid seal ring over turbine shaft and position it onto first groove. Use light finger pressure.
IMPORTANT!
The solid seal ring is made of a silicone-based material. This material will stretch during installation,
causing an increase in seal ring diameter. To ensure proper seal ring functioning the seal ring must
be resized. Use the sizing tool contained in the Turbine Shaft Seal Kit (Part No. 8-96041-327-0)
and the following two steps to resize the solid seal ring
^ Place Sizing tool over turbine shaft and push downward until tool contacts overrun clutch (Figure
2).
^ Wait five minutes, then remove and discard sizing tool.
REASSEMBLY
Reassemble in accordance with Section 7A of appropriate Workshop Manual.

PARTS INFORMATION
Part Number Description Quantity Required
8-9641-327-0 Turbine Shaft Seal Kit 1
Solid Seal Ring Sizing Tool Installation Instructions

Jul > 96 > A/T - (4L30E) Delayed Gear Engagement > Page 2589
Use the appropriate new labor operation as shown.
Labor time includes 0.1 administrative time allowance.

Component Information > Technical Service Bulletins > Customer Interest for Turbine Shaft: > SB96-05-L002 > Jul > 96 >
A/T - (4L30E) Delayed Gear Engagement
Turbine Shaft: Customer Interest A/T - (4L30E) Delayed Gear Engagement
GROUP: TRANSMISSION
TROOPER (UX) AND RODEO (UC) 4L30-E AUTOMATIC TRANSMISSION DELAYED GEAR
ENGAGEMENT
AFFECTED VEHICLES
All Trooper (UX) and Rodeo (UC) models equipped with 4L30-E automatic transmission.
SERVICE INFORMATION
Some affected vehicles may experience a noticeable delay from the time that gear selection is
made to the time that gear engagement occurs. This usually occurs after the vehicle has been
parked for an extended period of time (e.g., overnight) and only on the initial gear engagement
when shifting into drive or reverse. This delay may be caused by torque converter draindown.
This condition does not affect transmission operation, once the torque converter refills, and is not
harmful to the transmission. However, if it is necessary to eliminate this condition, replace the scarf
cut seal ring located on the first groove of the turbine shaft with a solid seal ring, using a Turbine
Shaft Seal Kit (Part No. 8-96041-327-0), in accordance with the procedure in this Service Bulletin.
NOTE
A short delay (i.e., 3 seconds or less) is normal when first engaging drive or reverse after allowing
the vehicle to sit overnight.
SERVICE PROCEDURE
DISASSEMBLY
Disassemble in accordance with Section 7A of appropriate Workshop Manual, to allow access to

turbine shaft seal rings.
REMOVAL
Scarf Cut Seal Ring

A/T - (4L30E) Delayed Gear Engagement > Page 2595
^ Remove scarf cut seal ring located in first groove of turbine shaft (Figure 1).
NOTE
The first groove is the groove closest to the torque converter.
INSTALLATION
Solid Seal Ring ^
Lubricate first groove of turbine shaft and solid seal ring (from Turbine Shaft Seat Kit) with
petroleum jelly.
^ Slip solid seal ring over turbine shaft and position it onto first groove. Use light finger pressure.
IMPORTANT!
The solid seal ring is made of a silicone-based material. This material will stretch during installation,
causing an increase in seal ring diameter. To ensure proper seal ring functioning the seal ring must
be resized. Use the sizing tool contained in the Turbine Shaft Seal Kit (Part No. 8-96041-327-0)
and the following two steps to resize the solid seal ring
^ Place Sizing tool over turbine shaft and push downward until tool contacts overrun clutch (Figure
2).
^ Wait five minutes, then remove and discard sizing tool.
REASSEMBLY
Reassemble in accordance with Section 7A of appropriate Workshop Manual.

PARTS INFORMATION
Part Number Description Quantity Required
8-9641-327-0 Turbine Shaft Seal Kit 1
Solid Seal Ring Sizing Tool Installation Instructions

A/T - (4L30E) Delayed Gear Engagement > Page 2596
Use the appropriate new labor operation as shown.
Labor time includes 0.1 administrative time allowance.

Isuzu Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Diagrams
Valve Body: Diagrams

MAIN CASE VALVE BODY
ADAPTER CASE VALVE BODY

Valve Body: Service and Repair
1. Drain transmission fluid, then remove oil pan and screen. 2. Disconnect oil pipe by raising
slightly with a screwdriver. 3. Remove valve body attaching bolts. Mark location of attaching bolts
to ensure correct position during installation. 4. Lower valve body slightly, then disconnect throttle
valve control cable from throttle cam. 5. Remove valve body from transmission. 6. To install,
connect throttle valve control cable to throttle cam, then align manual valve with pin on valve lever.
7. Install valve body and torque attaching bolts to 5.8-8.7 ft. lbs. 8. Install oil pan screen and torque
attaching bolts to 3.6-4.3 ft. lbs. 9. Install oil pipes, then the oil pan. Torque oil pan attaching bolts
to 2.9-3.6 ft. lbs.
10. Add transmission fluid as specified and check for proper operation.
MAIN CASE VALVE BODY
DISASSEMBLY 1. Gaskets and transfer plate
^ Remove two 11 mm bolts from valve body.
2. Manual valve 3. Band control solenoid 4. Pin 5. Waved washer 6. Spring pin 7. 1-2/3-4 solenoid
^ Remove solenoids by grasping the metal tip. Do not grasp the connector housing.
8. Retainer 9. 1-2/3-4 shift valve
10. Spring 11. Spring pin 12. 2-3 solenoid
^ Remove solenoids by grasping the metal tip. Do not grasp the connector housing.
13. Retainer 14. 2-3 shift valve 15. Spring 16. Spring pin 17. Plug 18. Spring 19. Low pressure
control valve
20. Spring pin 21. Plug 22. Band control screen assembly 23. Spring pin 24. Plug 25. 1-2
accumulator valve 26. 1-2 accumulator control valve 27. Check ball
^ Remove 1 check ball from valve body.
Inspect for the following and replace any damaged or worn parts:
^ Damage or wear to each valve.
^ Damage in oil passages.
^ Cracks or damage to valve body.
^ Valve operations.
^ Spring fatigue.
REASSEMBLY
27. Check ball
^ Install 1 check ball to valve body
26. 1-2 accumulator control valve 25. 1-2 accumulator valve 24. Plug 23. Spring pin 22. Band
control screen assembly 21. Plug 20. Spring pin 19. Low pressure control valve 18. Spring 17. Plug
16. Spring pin 15. Spring 14. 2-3 shift valve 13. Retainer 12. 2-3 solenoid 11. Spring pin 10. Spring
9. 1-2/3-4 shift valve 8. Retainer 7. 1-2/3-4 solenoid 6. Spring pin 5. Waved washer 4. Pin 3. Band
control solenoid 2. Manual valve 1. Gaskets and transfer plate
^ Install gasket (valve body/transfer plate) and transfer plate, using two guide pins (Fig. 7A - 66).
^ Install two 11 mm bolts. Torque: N.m (lb.in) 13 (113)

^ Install gasket (transfer plate/main case). Guide pins J-3387-2
Adapter Case Valve Body DISASSEMBLY
1. Converter clutch solenoid
^ Remove 11 mm bolt from valve body.

^ Remove converter control solenoid assembly with two 0-ring.
2. Retainer
^ Remove 11 mm bolt and retainer from valve body.
3. Force motor solenoid 4. Spring pin 5. Plug 6. 3/4 accumulator valve 7. 3/4 accumulator control
valve 8. Spring pin 9. Spring
10. Retaining ring 11. Feed limit valve 12. Spring pin 13. 0-ring 14. Plug 15. Force motor screen
assembly
^ Use 5 mm bolt to pull plug.

Inspect for the following and replace any damaged or worn parts:
^ Damage or wear to each valve.
^ Damage in oil passages.
^ Cracks or damage to valve body.
^ Valve operations.
^ Spring fatigue
REASSEMBLY
15. Force motor screen assembly 14. Plug 13. 0-ring 12. Spring pin 11. Feed limit valve 10.
Retaining ring 9.
Spring
8. Spring pin
7. 3/4 accumulator control valve
6. 3/4 accumulator valve
5. Plug
4. Spring pin
3. Force motor solenoid
2. Retainer ^
Place solenoid terminals pointing towards mating face.
^ Install retainer and bolt. Torque: N.m (lb.in) 10 (87)
1. Converter clutch solenoid
^ Install converter clutch solenoid assembly with two 0-rings to valve body.
^ Install bolt. Torque: N.m (lb.in) 10 (87)

Isuzu Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Damper > Component Information >
Clutch Damper: Description and Operation

Isuzu Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Damper > Component Information >
Clutch Damper: Service and Repair
Bleeding the Damper Cylinder
(1) Check the level of clutch fluid in the reservoir and replenish if necessary. (2) Remove the rubber
cap from the bleeder screw and wipe clean the bleeder screw. Connect a vinyl tube to the bleeder
screw and insert the other
end of the vinyl tube into a transparent container.
(3) Pump the clutch pedal repeatedly and hold it depressed. (4) Loosen the bleeder screw to
release clutch fluid with air bubbles into the container, then tighten the bleeder screw immediately.
(5) Release the clutch pedal carefully. Repeat the above operation until air bubbles disappear from
the clutch fluid being pumped out into the
container. During the bleeding operation, keep the clutch fluid reservoir filled to the specified level.
Reinstall the rubber cap.
Isuzu Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid >
Clutch Fluid: Specifications
Type .....................................................................................................................................................
.................................... DOT-3 hydraulic brake fluid
Isuzu Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder
> Component Information > Service and Repair
Clutch Master Cylinder: Service and Repair
1. Disconnect hydraulic line from master cylinder.
2. Remove master cylinder retaining bolts, then the pin and jaw joint pin from the pedal assembly.
3. Reverse procedure to install, noting the following: a. Bleed clutch hydraulic system. Refer to
See: Service and Repair b. Note the master cylinder push rod lock nut position and adjust new
master cylinder assembly accordingly.
Isuzu Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Clutch Slave Cylinder: Service and Repair
2. Disconnect hydraulic line from slave cylinder.
3. Remove slave cylinder retaining bolts, then the slave cylinder from transmission case.
4. Reverse procedure to install, noting the following: a. Bleed clutch hydraulic system. Refer to
See: Service and Repair
Isuzu Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information
> Diagrams
Isuzu Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information
> Diagrams > Page 2623
Clutch Pedal Assembly: Adjustments
1. On models with cruise control, remove clutch switch connector then loosen locknut and turn
switch out until there is a gap between switch
plunger and clutch pedal.
2. On models less cruise control, loosen clutch pedal adjusting bolt. 3. Loosen clutch master
cylinder pushrod locknut then turn pushrod by hand to set clutch pedal height to 7.6-8.0 inches. 4.
Tighten pushrod locknut. 5. On models with cruise control, proceed as follows:
a. Turn clutch switch until switch plunger is fully retracted against clutch pedal arm. b. Turn out
switch one-half turn, then lock clutch switch locknut. c. Connect clutch switch connector.
6. On models less cruise control, tighten clutch pedal adjusting bolt until bolt contacts clutch pedal
arm. 7. Ensure clutch pedal freeplay is 0.2-0.6 inch, if freeplay is not within specifications, repeat
steps three through eight.
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component
Differential Carrier: Service and Repair
1. On models less locking differential, proceed as follows:
a. Install thrust washers on side gears and mount side gears in case. Lubricate all components with
specified gear lubricant prior to
assembly.
b. Position one differential pinion (less thrust washer) between side gears and rotate gears until
pinion is directly opposite case loading opening. c. Install other pinion with pinion shaft holes
aligned, then rotate side gears and ensure pinions align with shaft openings in case. d. When
pinions are properly aligned, rotate pinions toward loading opening just enough to allow thrust
washer installation and install washers. e. Align pinions with shaft opening in case, insert pinion
shaft through case, install new lockpin.
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component
Fig. 9 Locking Differential
2. On models with locking differential, refer to Fig. 9 for reassembly procedure. If it was necessary
to replace cam gear, side gear or thrust block
the following adjustments must be performed in order as listed.
3. Cam side gear adjustment:
a. Install cam side gear and thrust washer into case, then install pinion gears and cross shaft.
Install cross shaft lock bolt. b. Rotate the lock bolt side pinion gear until a tooth is perpendicular to
the ring gear mounting surface, then insert a large tapered tool between
cross-shaft and cam gear face to eliminate freeplay.
c. Using a dial gauge measure lock bolt side pinion gear backlash, repeat steps b and c for
opposite side pinion gear. d. Adjust backlash to 0.010 to 0.018 inch by selecting cam gear thrust
washer.
4. Right side gear backlash:
a. Install clutch plates w/clips, right side gear and thrust washer into case then install pinion gears
and cross shaft. Install cross shaft lock bolt. b. Rotate the lock bolt side pinion gear until a tooth is
perpendicular to the ring gear mounting surface, then insert a large tapered tool between
cross-shaft and cam gear face to eliminate freeplay.
c. Using a dial gauge measure lock bolt side pinion gear back lash, repeat steps b and c for
opposite side pinion gear. d. Adjust backlash to 0.002 to 0.010 inch by selecting cam gear thrust
washer.
5. Thrust block clearance:
a. Install cam side gear and thrust washer into case. Install clutch plates w/clips, right side gear and
thrust washer into case. Install cross shaft
only, then insert two large tapered tools between cross-shaft and gear faces to eliminate freeplay.
b. With a 1-2 inch telescoping gauge, measure the distance between gear faces not gear teeth,
record measurement. c. With a 1-2 inch micrometer, measure thickness of the thrust block at an
unworn outer corner. d. Adjust thrust block to gear clearance to 0.000-0.006 inch by selecting
either a new thrust block or shimming right of cam gear clutch pack. If
shims are used, pinion gear backlash must remain between 0.002-0.010 inch.
6. Ensure ring gear and case mating surfaces are clean and free from burrs, mount ring gear on
case, install two new retaining bolts at opposite sides
of gear and alternately tighten bolts to draw gear on case.
7. Install remaining ring gear bolts hand tight and ensure gear is squarely seated on case. Always
use new bolts of proper type when installing ring
gear. Do not reuse old bolts.
8. Alternately torque ring gear bolts to 80-90 ft. lbs. 9. Press side bearings onto case. If old
bearings are reused, ensure bearings are installed in original position.
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Differential Case: Service and Repair
1. On models less limited slip differential, install side gears and thrust washers in differential case.
Fig. 22 Positioning pinion gears
2. Position pinion gears 180° apart, Fig. 16, then roll gears into position, making sure they are
aligned, to allow installation of pinion shaft. 3. Place thrust block between pinion gears and drive
pinion into place. Make sure the lockpin hole in the cross shaft lock aligns with hole in case. 4.
Check backlash between differential gears and pinion gears. If backlash is greater than .003 inch,
make necessary adjustments with thrust washers.
Thrust washers are available in thicknesses of .041, .045, .049 and .053 inch. Increasing washer
thickness will decrease backlash. Decreasing washer thickness will increase backlash.
Fig. 23 Installing lockpin
5. Install cross shaft lockpin, Fig. 17, then caulk end to avoid loosening.
Fig. 18 Dimensions A, B, & C Measurement
6. On models with limited slip differential, to set differential housing to carrier housing clearance,
measure dimensions A, B and C, Fig. 18, then
place pinion cross shaft in pressure rings, install friction plates and discs on pressure rings and
measure dimension D Fig. 19.
7. Measure thickness of a spring disc and multiply by 4, this will equal dimension E. Using formula
(A - B) + C - (D + E) = X, select friction discs or
plates to adjust dimension D to give a result of 0.002 to 0.008 inch for X. Variance in thickness of
friction discs or plates should not exceed 0.020 inch.
Fig. 21 Dimensions B,F & G Measurement
8. To set backlash, proceed as follows:
a. Place pinions on cross shaft, then install cross shaft assembly and side gears into pressure
rings. b. With side gear thrust washers held into place, measure dimension H Fig. 20. c. Using the
formula (F - B) + (G - H) = Y, select thrust washers to adjust dimension H to give a result of 0.002
to 0.008 inch for Y.
d. Measure dimensions F and G Fig. 21. e. Select thrust washers so that variance in dimension of
each half of the assembly does not exceed 0.002 inch.
Fig. 22 Spring Disc Position
9. Refer to Fig. 22. for assembly sequence. Ensure spring discs are installed correctly, Fig. 22.
Fig. 24 Ring gear bolts tightening sequence. Rear differentials

Fig. 24 Ring Gear Bolts Tightening Sequence
10. Clean ring gear bolts then apply Loctite to threaded portion of bolts. Install ring gear, then install
and torque bolts to 80-87 ft. lbs. for rear
differentials or 44-58 ft. lbs. for front differentials in sequence shown in Figs. 23 and 24.
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Cleaning & Inspection
Differential Axle Housing: Service and Repair Cleaning & Inspection
1. Clean components in solvent and blow dry with compressed air, noting the following:
a. Do not use brush when cleaning bearings. b. Do not spin dry bearings, as bearings will be
damaged. c. Lightly lubricate components after cleaning to retard corrosion. d. Keep all
components in order to ensure proper assembly.
2. On models less locking differential inspect gears for cracks, chipped teeth, wear and scoring,
and damaged bearing or mounting surfaces.
Replace gears that are damaged or excessively worn. Ring gear and pinion must be replaced as
an assembly.
3. Inspect differential case for cracks, damage, worn side gear bores and scored bearing surfaces
and replace as needed. 4. On models with locking differential, inspect gears for cracks, chipped
teeth, wear and scoring, and damaged bearing or mounting surfaces.
Inspect the side gear bore in differential case for scoring, if scoring is present replace entire
assembly.
5. Inspect housing for scored bearing mount surfaces, cracks and distortion, and replace as
needed. 6. Inspect bearing rollers and races for pitting, scoring, overheating and damage. 7. Mate
bearing with race and check operation. 8. Replace any bearing that is damaged, excessively worn
or that fails to operate smoothly. 9. Mount differential case along with side bearings and ring gear in
housing, and check run out with side bearings adjusted for zero preload and a dial
indicator positioned against machined edge of ring gear.
10. If run out exceeds .003 inch, and gear cannot be positioned to eliminate run out, ring gear
and/or case should be replaced.
Information > Service and Repair > Cleaning & Inspection > Page 2640
Differential Axle Housing: Service and Repair Rear Differential
Fig. 1 Exploded view of rear differential
Refer to Fig. 1, during disassembly and assembly of the rear differential carrier. Do not
disassemble ring gear assembly. Remove only parts required for replacement or inspection. Note
position and quantity of shims.
Information > Service and Repair > Cleaning & Inspection > Page 2641
Differential Axle Housing: Service and Repair Rear Axle Housing
1. Raise and support vehicle by frame. 2. Remove rear wheels and drums, then the lower shock
absorber mounting bolts. 3. Mark propeller shaft and pinion flange position for installation. 4.
Remove propeller shaft to rear axle retaining bolts, then support shaft out of way. 5. Disconnect
speed sensor electrical connectors. 6. Disconnect brake lines at rear axle housing, then at rear of
backing plates. 7. Support rear axle assembly, then remove rear axle U-bolts and anchor plates. 8.
Lower axle housing from vehicle. 9. Reverse procedure to install, noting the following:
a. Tighten rear axle U-bolts in two steps. Torque U-bolts in a diagonal pattern to 18 ft. lbs., then
torque U-bolts in same diagonal pattern to 49
ft. lbs.
b. Align marks on propeller shaft and pinion flange, then torque retaining bolts to 46 ft. lbs. c.
Torque shock absorber retaining nuts to 29 ft. lbs.
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Fluid - Differential: Capacity Specifications
1990-94 W/Saginaw rear axle

.......................................................................................................................... 80W-90 GL-5(Gear
Oil, API Service GL-5) All Others ........................................................................................................
.............................................................................................................. GL-5
Above 50°F (10°C) ..............................................................................................................................

............................................................................ 140 0° to 90°F (-18° to 32°C) .................................
..............................................................................................................................................................
.... 90 Below 50°F (10°C) .....................................................................................................................
.............................................................................. 80W-90
CAPACITY, Refill: Front ......................................................................................................................

................................................................................. 1.5 liters 3.2 pints Rear:
2.3L ......................................................................................................................................................
............................................ 1.5 liters 3.2 pints 2.6L, 2.8L, 3.1L, 3.2L ................................................
...................................................................................................................... 1.8 liters 3.8 pints All
with Saginaw axle ................................................................................................................................
....................................... 1.9 liters 4.0 pints
Saginaw axle has removable rear cover without fill plug.

Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Fluid - Differential: Fluid Type Specifications
OIL VISCOSITY CHART FOR FRONT AXLE AND REAR AXLE
TYPE ...................................................................................................................................................
.................................................. GL-5 gear lubricant
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Pinion Installation
Pinion Gear: Service and Repair Pinion Installation
1. Install selected shim onto pinion shaft, lubricate rear pinion bearing with specified axle lubricant,
then press rear bearing onto pinion using suitable
spacers.
2. Install new collapsible spacer onto pinion shaft, then insert pinion assembly into housing. 3.
Lubricate front pinion bearing, install bearing into housing and tap bearing over pinion shaft with a
drift while assistant holds pinion in place. Old
pinion nut and a large washer can be used to seat front bearing on pinion, but care must be taken
not to collapse spacer if this method is used.
4. Install new pinion seal in housing, coat seal lips with grease, then mount driveshaft yoke on
pinion shaft, lightly tapping yoke until several pinion
shaft threads protrude from yoke.
5. Coat rear of pinion washer with suitable sealer, then install washer and new pinion nut. 6. Hold
driveshaft yoke with suitable tool, then alternately tighten pinion nut and rotate pinion until endplay
is reduced to zero. 7. When endplay is reduced to zero, check pinion bearing preload using a
torque wrench. 8. Continue tightening pinion nut in small increments until specified pinion bearing
preload is obtained, rotating pinion and checking preload after
each adjustment. Exceeding preload specification will compress collapsible spacer too far,
requiring replacement of spacer. If preload specification is exceeded, spacer must be replaced and
adjustment procedure must be repeated. Do not loosen pinion nut to reduce preload.
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Pinion Installation > Page 2651
Pinion Gear: Service and Repair Drive Pinion
1. Remove differential, then scribe a reference mark between drive pinion and driveshaft yoke, then
hold yoke with suitable tool and remove pinion
nut and yoke. If yoke shows wear in the seal-to-flange contacting surface, the yoke should be
replaced.
2. Install original pinion nut a few turns on pinion shaft, then using hammer and drift, tap pinion
shaft out of pinion housing. Hold gear end of
pinion shaft when removing to prevent it from falling from axle housing. Pinion preload shims must
be collected and kept together for use during reassembly.
3. Remove and discard pinion nut and collapsible spacer. 4. If being replaced, remove front and
rear bearing races from pinion housing using drift positioned in race slots and hammer. 5. If rear
pinion bearing is being replaced, remove using arbor press and adapters. Measure and record
thickness of shim which is found under rear
bearing.
Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Ring Gear: Service and Repair
1. Raise and support rear of vehicle, then loosen axle housing cover bolts and allow lubricant to
drain into suitable container. 2. Remove axle housing cover, then proceed as follows:
a. Wipe excess lubricant from inside axle housing, then visually inspect parts for wear and/or
damage. b. Rotate gears and check for roughness, indicating damaged bearings or gears. c. Install
dial indicator on axle housing cover flange, then check and record ring gear to drive pinion
backlash.
3. Remove rear axles and propeller shaft. 4. If not previously marked, scribe reference marks on
differential bearing caps to be used during reassembly, then loosen bearing cap bolts. 5. Using
suitable tool, pry differential case, bearing races and shims out of housing until loose in the bearing
caps. Remove bearing races, then the
differential assembly. Mark side cups and shims for reference during reassembly.
6. If side carrier bearings are to be replaced, remove bearings using a bearing puller. 7. Remove
ring gear bolts, then the ring gear, driving ring gear from case using drift and hammer. Ring gear
bolts have left hand threads. Do not
pry between ring gear and case, as mating surfaces will be damaged.
8. On models less locking differential, proceed as follows:

a. Remove differential pinion shaft lock bolt and the pinion shaft. b. Remove differential pinions and
thrust washers, side gears and side gear thrust washers, noting installation position for assembly.
Keep thrust
washers with respective gears.
Fig. 8 Governor Bushing Removal

Isuzu Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Fig. 9 Locking Differential
9. On models with locking differential, remove governor bushing Fig. 8 using governor removal tool
No. J-26252, or equivalent. Remove and store
remaining components in order shown in Fig. 9, for later inspection and/or reassembly.
10. Inspect components as outlined in Inspection and replace as needed.

Isuzu Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Saginaw
Axle Bearing: Service and Repair Saginaw
AXLE SHAFT
SAGINAW
- Raise the vehicle.
1. Rear wheels and brake drums. 2. Axle housing cover.
- Clean all dirt from the axle housing cover area.
3. Pinion shaft lock bolt. 4. Pinion shaft. 5. "C" lock from the button end of the axle shaft.
- Push the axle shaft in toward the center of the vehicle.
6. Axle shaft from the axle housing.
- Mark the shaft as left or right.

Information > Service and Repair > Saginaw > Page 2661
OIL SEAL and/or BEARING
REMOVE
Tools required:
J-2619-01 Slide Hammer J-22813-01 Axle Bearing Puller
1. Axle Shaft 2. Oil seal using a pry bar behind the steel case of the oil seal. Be careful not to
damage the housing.
3. Bearing using J-2619-01 and J-22813-01. The tangs of the tool should engage the bearing outer
race A.
INSTALLATION
Tools Required:
J-8092 Driver Handle J-23765 Axle shaft Bearing Installer J-23771 Axle Shaft Seal Installer
1. Bearing with J23765 and J-8092, until the tool bottoms against the housing shoulder. Lubricate
the bearing with gear lubricant.
2. Oil seal using J-23771 until the oil seal is flush with the axle tube. Lubricate the seal lips with
gear lubricant. 3. Axle shaft.
AXLE SHAFT
INSTALL OR CONNECT
1. Axle shaft into the housing.

- Be sure to use the correct axle on its corresponding side.
- Be careful not to damage the oil seal.
- The splines at the end of the axle shaft must engage with the splines of the rear axle side gear.
2. "C" lock on the axle shaft.
- Pull the axle shaft outward so the "C" lock seats in the counterbore of the rear axle side gear.
3. Pinion shaft through the case and the pinions.
- Align the hole in the pinion shaft with the lock bolt hole.
IMPORTANT: Anytime a differential pinion shaft locking screw is removed, it is important to coat
the screw threads with Loctite(tm) 242 before reinstalling. These screws are coated with an
adhesive which helps to prevent the screw from loosening in the case. When this screw is
removed, the adhesive is also removed.
4. New lock bolt.
- Tighten: Lock bolt to 34 Nm (25 ft. lbs.).
5. New gasket on the axle housing cover. 6. Axle lubricant to a level 9.5 mm (3/8 inch) from the top
of the fill plug hole. 7. Brake drum and wheel.
- Check rear axle operation.

Axle Bearing: Service and Repair Dana
AXLE SHAFT, OIL SEAL AND BEARING AXLE SHAFT AND ASSOCIATED PARTS
DANA
Disc Brake Model
Drum Brake Model
REMOVAL
1. Raise the vehicle. 2. Remove rear wheels and brake calipers or drums. Do not let calipers hang
from the vehicle by the brake line or hose. Wire them to frame of
vehicle to prevent damage.
3. Remove four nuts and lockwashers. 4. Remove shaft assembly from the axle housing. 5.
Remove snap ring and bearing cup.
6. Break retainer ring with hammer and chisel.
7. Break bearing cage with hammer and chisel. 8. Remove oil seal, retainer, and emergency brake
assembly.
9. Remove inner race from shaft with OTC-1126 bearing splitter and press.
INSPECTION
- Shaft for spalling or grooves from seal wear.
- Retainer - bent or damaged.
- Replace items if required.
INSTALLATION
1. Emergency brake assembly.

2. Install retainer. Note direction - do not install backwards. 3. Install oil seal. Note direction.
4. Install bearing assembly, using installer and press.
NOTE: Install bearing with cup towards inboard side.

5. Install retainer ring, using installer and press. 6. Install snap ring. 7. Install axle shaft assembly
into housing. 8. Install bolts, lockwashers, and nuts. Tighten the retainer nuts to the specified
torque.
Torque: 75 Nm (55 ft. lbs.)

Isuzu Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Rear
Axle Shaft: Service and Repair Rear
AXLE SHAFT, OIL SEAL AND BEARING
REMOVAL (Fig. 4B1-4, 4B1-4a, 4B1-5, 4B1-6, 4B1-7)
Tools Required
^ Bearing Splitter or equivalent.
^ Bearing installer (Steel pipe 25.5 inches long, 2.000 inches O.D., 1.625 inches I.D.)
^ Shop press
Raise the vehicle.
1. Rear wheels and brake calipers or drums. Do not let calipers hang from the vehicle by the brake
line or hose. Wire them to frame of vehicle to
prevent damage.
2. Four nuts (11) and lockwashers (10). 3. Shaft assembly from the axle housing. 4. Snap ring and
bearing cup.
5. Break retainer ring with hammer and chisel, (Fig. 4B1-5).

Shaft > Component Information > Service and Repair > Rear > Page 2672
6. Break bearing cage with hammer and chisel (Fig. 4B1-6).
Bearing cage, and rollers.
7. Oil seal, retainer, and emergency brake assembly.
INSPECTION
Shaft for spalling or grooves from seal wear. Retainer - bent or damaged. Replace items if
required. 8. Inner race from shaft with OTC-1126 bearing splitter and press (Fig. 4B1-7).
INSTALLATION (Fig. 4B1-8)
1. Emergency brake assembly. 2. Retainer (Fig. 4B1-8). Note direction - do not install backwards.
3. Oil seal. Note direction. 4. Bearing assembly (Fig. 4B1-8A), using installer and press.
Note: Install bearing with cup towards inboard side (Fig. 4B1-8B).
5. Retainer ring (Fig. 4B1-8C), using installer and press.
6. Snap ring. 7. Axle shaft assembly into housing.

8. Bots, Lockwashers (10), and Nuts (12) (Fig. 4B1-13).
Retainer nuts

Isuzu Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Disassembly
Constant Velocity Joint: Service and Repair Disassembly
Double Offset Joint
1. Remove DOJ inner and outer boot clamps then slide boot towards Birfield Joint assembly.
Fig. 1 Ball From Joint Removal
2. Remove circular clip and withdraw shaft, then using a screwdriver, remove six balls, Fig. 1. 3.
Rotate case half a pitch to ensure ball guide aligns with projected portion of ball retainer, then slide
towards boot to remove.
Fig. 2 Ball Retainer & Guide Replacement
Fig. 12 Removing or installing snap ring
4. Remove snap ring holding ball retainer on center shaft, then the ball retainer along with cage
and boot, Figs. 2 and 3.
Constant Velocity Joint > Component Information > Service and Repair > Disassembly > Page 2679
5. Inspect all parts for abnormal wear, cracks and damage.
Birfield Joint
The Birfield joint is non-serviceable with the exception of boot replacement.
1. Disassemble and remove joint assembly from center shaft. 2. Remove boot clamps and slide
boot towards inboard side of center shaft to remove. 3. Inspect all parts for abnormal wear, cracks
and damage.
Constant Velocity Joint > Component Information > Service and Repair > Disassembly > Page 2680
Constant Velocity Joint: Service and Repair Assembly
Birfield Joint
1. Slide boot onto center shaft from inboard side taking care not to damage. 2. Fill boot half way
with suitable lubricant then lubricate ball grooves. 3. Position boot over Birfield joint assembly
ensuring boot is not collapsed, then install boot clamps.
Double Offset Joint
1. Install small boot clamp center shaft, then install boot and slide towards Birfield joint assembly.
Fig. 12 Removing or installing snap ring
2. Install case small diameter side first onto center shaft, then install ball retainer and secure with
snap ring, Fig. 3.
Fig. 2 Ball Retainer & Guide Replacement
3. Line up ball guide of cage with projected portion of ring on ball retainer, then turn cage half pitch.
Align track on ball retainer with cage window
and place six balls in position, Fig. 2.
4. Fill boot half way with suitable lubricant and install over Double Offset Joint assembly ensuring it
does not collapse, then install boot clamps.
Isuzu Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Adjustments > Automatic Locking Hub
Isuzu Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Adjustments > Automatic Locking Hub > Page 2685
washer.
Available
Isuzu Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component ..........................................................................................................................................
..............................................................................................................................................................
. 76 Axle Nut ........................................................................................................................................
..................................................................................... 76 Driveshaft Nut ...........................................
..............................................................................................................................................................
........... 76 Hub Nut ..............................................................................................................................
..............................................................................................................................................................
(Front Bolt) ...........................................................................................................................................
Frame ..................................................................................................................................................
.................................................................................................................................. 61 Stabilizer Bar
.......................................................................................................................................... 8 Steering
Knuckle ................................................................................................................................................
................................................................................................................................................... 73
.............................................................................................................................................................
.................................................................................... 80 Wheel Lug Nuts .........................................
..............................................................................................................................................................
........ [01]
Isuzu Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) >
Component Information > Technical Service Bulletins > Locking Hub - Special Tool
AFFECTED VEHICLES
SERVICE INFORMATION
J-29015.
Component Information > Service and Repair > Automatic Locking Hub
REMOVAL
1. Bolt
Lockwasher
Component Information > Service and Repair > Automatic Locking Hub > Page 2696
8. Hub nut
Wrench: J-36827
13. Bolt
14 Wheel pin
- Hub
- Knuckle spindle
- Disc
- Caliper

14. Wheel pin
completely.
13. Bolt

11. Oil seal
8. Hub nut
Wrench: J-36827
Preload adjustment
7. Lock washer
washer.
6. Inner cam
Installer: J-38194
Shim selection

washer.
of the axle shaft.

shaft.

correct.

DISASSEMBLY
knob.
ASSEMBLY

three feet.

Manual Locking Hub

Isuzu Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair
Drive/Propeller Shaft: Service and Repair
1. Mark flange for driveshaft alignment during installation.
Fig. 1 Driveshaft Removal
2. Remove differential side and transfer side bolts, Fig. 1. 3. Remove rear side and front side
assemblies.
Isuzu Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Page 2715
Fig. 2 Driveshaft Setting Marks
4. Reverse procedure to install, noting:
a. Align setting marks, (3 mm punched holes) on shaft and splined yoke, Fig. 2. b. Torque transfer
side and differential side bolts to 46 ft. lbs.
Isuzu Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair
Universal Joint: Service and Repair
REMOVAL
- Raise the vehicle on a hoist.
- Support the propeller shaft together with center support bearing.
- Do not allow the universal joint to bend deeply, as universal joint could fracture.
1. 2nd propeller shaft 2. Center support bearing
- Detach the outer retainer of center support bearing and remove the center support bearing with
special tool Center support bearing remover: J-22888.
3. 1st propeller shaft 4. Bolt

Drive/Propeller Shaft > Component Information > Service and Repair > Page 2719
- Apply a reference mark to the yoke flange at pinion flange connection.

5. Nut 6. Washer 7. Washer 8. Bolt 9. Locknut
10. Washer 11. End yoke 12. Bolt
- Apply a reference mark to the end yoke at drive shaft connection
13. Bearing strap
INSTALLATION
To install, follow the removal procedure in the reverse order, noting the following steps; 1. Tighten
the companion flange lock nut (9).
Torque N.m (Ib ft.) 152(112).
2. Tighten the retainer bolt (12).
Torque N.m (lb.ft.) 21(15.5)
3. Tighten the flange nut (5).
Torque N.m (lb.ft.) 63 (46)

DISASSEMBLY
1. 1st and 2nd propeller shaft assembly 2
Spline yoke (MIT model only)

3 Dust cover
4. Spider 5. Flange yoke 6. Snap ring
Remove the snap rings by using pliers. 7. Bearing
- Remove the bearing by tapping the yoke with a mallet. If the snap ring is stuck in position, remove
paint from the hole in the yoke or tap around the edge of the bearing lightly with a mallet.
- After disassembly, clean all parts.
INSPECTION
- Slip yoke splines for wear.
- Outer diameter of spline yoke for burrs.
- Universal joint bearings and spider for wear and play.

- Propeller shaft for run out
Servicing value is 0.5 mm (0.02 in.) Or more.
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points;
- Apply a molybdenum-disulfide grease or a multi purpose type grease NLGI No.2 to the bearing
inner surface.
2. Assemble the spider to the yoke insert bearing into hole by using a wood block and brass
hammer or a press.
CAUTION: The needle roller bearing cannot be installed smoothly if it is set at an incorrect angle to
the flange. Excessive hammering will damage the needle roller bearing.
CENTER SUPPORT BEARING (REAR PROPELLER SHAFT) REMOVAL
1. Lock nut (9) and washer (10) from propeller shaft (3).
- Clamp front propeller shaft in a soft-jawed vise.
2. End yoke (11) from propeller (3).
- Apply a reference mark to the end yoke at drive shaft connection.
- Use a suitable puller.
3. Center support bearing (2) from propeller shaft (3).
- Use a special tool, Center Support Bearing Remover; J-22888
NOTE: Clean all parts after removal.
INSTALLATION
1. New center support bearings (2) onto the propeller shaft. Repack the bearing with grease. 2.
Endyoke (11).
- Align the reference marks on the end yoke and drive shaft.
3. Washer (10) and lock nut (9).
Lock nut torque N.m (lb.ft.) 152(112)

Isuzu Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flexplate To Crankshaft N.m (lb.ft) 54 (40)
..............................................................................................................................................................
.........
Isuzu Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
Flywheel To Crankshaft N.m (lb.ft) 54 (40)
..............................................................................................................................................................
..........
Isuzu Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps
and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation
CIRCUIT DESCRIPTION
and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation > Page 2733
CIRCUIT DESCRIPTION
257°F (125°C).
CIRCUIT DIAGRAM

and Indicators - A/T > Malfunction Indicator Lamp - A/T > Component Information > Description and Operation > Page 2734

and Indicators - A/T > Shift Indicator > Component Information > Description and Operation
Shift Light Circuit
PURPOSE
LOCATION
OPERATION
and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation
Isuzu Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Fluid - M/T: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage
GROUP MISCELLANEOUS
AFFECTED VEHICLES
SERVICE INFORMATION

Fluid - M/T: Capacity Specifications
BW Type Manual Transmission
Capacity ...............................................................................................................................................
.................................................. 2.25 Liter (2.4 qts.)
MUA Type Manual Transmission
Capacity ...............................................................................................................................................
.................................................. 2.95 Liter (3.1 qts.)
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid
Ambient Temperature >90°F ...............................................................................................................

............................................................ SAE 40 Other Areas ...............................................................
............................................................................................................................... SAE 5w/30*
*Preferred
Isuzu Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Module Identification
GROUP TRANSMISSION

CHART
AFFECTED VEHICLES
SERVICE INFORMATION

column.
CODE column.
NUMBER column.


PURPOSE
conditions.
OPERATION
shifting.
malfunction.
Isuzu Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Barometric Pressure Sensor, A/T > Component Information > Locations

and Switches - A/T > Downshift Switch, A/T > Component Information > Locations

and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
PURPOSE
OPERATION
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications
APPROX. RESISTANCE
@ -40°F (-40°C) ..................................................................................................................................

..................................................... 672 K ohms @ 32°F (0°C) .............................................................
................................................................................................................................. 65 K ohms @
68°F (20°C) .........................................................................................................................................
................................................... 25 K ohms @ 176°F (80°C) .............................................................
............................................................................................................................ 2.5 K ohms @
248°F (120°C) .....................................................................................................................................
..................................................... 780 ohms @ 302°F (150°C) ..........................................................
................................................................................................................................ 370 ohms
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page
2775
Isuzu Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
W/Manual Transmission
.....................................................................................................................................................
SG(Motor Oil, API Service SG)
Above 90°F (32°C) ..............................................................................................................................

........................................................................ 40 All temperatures ....................................................
................................................................................................................................................ 5W-30
W/Automatic Transmission:
4-cyl. ....................................................................................................................................................
....................................................................... AF V6 ...........................................................................
.................................................................................................................................................... SG
Above 90°F (32°C) ..............................................................................................................................

.............................................................................. 40 All temperatures ..............................................
............................................................................................................................................................
5W-30
CAPACITY, Refill: Man. trans ..............................................................................................................

................................................................................. 1.5 liters 3.2 pints Auto. trans.:
4-cyl. ....................................................................................................................................................
............................................. 0.8 liters 1.6 pints V6 .............................................................................
........................................................................................................................ 1.5 liters 3.2 pints
Isuzu Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications > Page 2781
Fluid - Transfer Case: Fluid Type Specifications

Isuzu Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids -
> Technical Service Bulletins > Customer Interest for Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T - Clunking
Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
> Technical Service Bulletins > All Technical Service Bulletins for Band Control Solenoid Valve: > 9305014 > Jul > 93 > A/T
- Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
RESISTANCE

....................................................................................................................................... below 7
ohms
Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing
and Inspection
terminal locations.
Isuzu Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators -
CIRCUIT DESCRIPTION
CIRCUIT DESCRIPTION
257°F (125°C).
CIRCUIT DIAGRAM


Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Description and
Operation
Shift Light Circuit
PURPOSE
LOCATION
OPERATION
Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Isuzu Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules -
Service Bulletins > A/T - (4L30E) Control Module Identification
GROUP TRANSMISSION

CHART
AFFECTED VEHICLES
SERVICE INFORMATION

column.
CODE column.
NUMBER column.


PURPOSE
conditions.
OPERATION
shifting.
malfunction.
Isuzu Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches -
Transmission and Drivetrain > Sensors and Switches - A/T > Barometric Pressure Sensor, A/T > Component Information >
Locations
Transmission and Drivetrain > Sensors and Switches - A/T > Downshift Switch, A/T > Component Information > Locations

Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
PURPOSE
OPERATION
APPROX. RESISTANCE
@ -40°F (-40°C) ..................................................................................................................................

..................................................... 672 K ohms @ 32°F (0°C) .............................................................
................................................................................................................................. 65 K ohms @
68°F (20°C) .........................................................................................................................................
................................................... 25 K ohms @ 176°F (80°C) .............................................................
............................................................................................................................ 2.5 K ohms @
248°F (120°C) .....................................................................................................................................
..................................................... 780 ohms @ 302°F (150°C) ..........................................................
................................................................................................................................ 370 ohms
Isuzu Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Isolation/Dump
Valve <--> [Brake Fluid Accumulator] > Component Information > Service and Repair
Isolation/Dump Valve: Service and Repair
1. Raise and support vehicle. 2. Disconnect harness connector. 3. Disconnect brake lines from
valve assembly. 4. Remove isolation/dump valve retaining bolts, then valve assembly from vehicle.
a. Torque isolation valve retaining bolts to 18 ft. lbs. b. Torque brake line flare nuts to 12 ft. lbs. c.
Bleed brake system.
Isuzu Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair



Control Module > Component Information > Diagrams > Page 2876
Isuzu Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair
lbs.
Isuzu Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair
ventilated.

Isuzu Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments
Brake Pedal Assy: Adjustments
Fig. 5 Adjusting brake pedal.
1. Measure brake pedal height and freeplay, Fig. 3, with brake pedal fully released. 2. Pedal height
should be 6.85-7.24 inches. Pedal freeplay should be .23-.35 inch. 3. If measurements are not
within specifications, adjust brake pedal as follows:
a. Disconnect stop lamp switch. b. Loosen pushrod locknut. c. Rotate pushrod as needed to bring
pedal height within specifications, then torque locknut to 13-16 ft. lbs. d. Install stop lamp switch.
Adjust clearance between switch housing and brake pedal to 0.02-0.04 inch. e. Check that pedal
freeplay is within specifications.
Isuzu Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams >
Diagram Information and Instructions
Brake Warning Indicator: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Diagram Information and Instructions > Page 2890

Brake Warning Indicator: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Brake Warning System
Isuzu Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Caliper Bore Diameter
Brake Caliper: Specifications
Front Caliper Bore Dia. 2.375 in

Specifications > Caliper Bore Diameter > Page 2916
Brake Caliper: Specifications Torque Specifications
Bleeder Screw 5.5 ft.lb
Caliper Bracket 115 ft.lb
Caliper Guide Pin Bolt 54 ft.lb
Flexible Brake Hose To Brake Line 12 ft.lb
Flexible Brake Hose To Caliper 26 ft.lb
Caliper Bracket 69-84 ft.lb
Caliper Slide Pin Lock Bolt 121-17 ft.lb
Flexible Hose To Line 11 ft.lb
Flexible Hose To Caliper 14 ft.lb
Bleeder Screw 6 ft.lb
Caliper Slide Pin Lock Bolt 32 ft.lb

Service and Repair > Front Caliper
Brake Caliper: Service and Repair Front Caliper
Removal and Installation
Removal
1. Perform steps one through three as outlined under Brake Pad Service And Repair procedure.
See: Brake Pad/Service and Repair 2. Disconnect brake hose from caliper and cap openings in
hose and caliper. 3. Remove caliper from vehicle.
Installation
1. Perform steps one through three as outlined under Brake Pad Service And Repair installation
procedure. See: Brake Pad/Service and Repair 2. Connect brake hose to caliper, then bleed brake
system. 3. Install wheel assembly and lower vehicle.
Disassembly and Reassembly
Fig. 2 Front Caliper, Exploded View
Refer to Fig. 2 for front caliper overhaul.
1. Remove guide and lock bolts from caliper. 2. Remove dust seal from caliper with a small
screwdriver. 3. Place a block of wood into caliper and force piston from caliper with compressed air
applied to the fluid port. 4. Remove piston square sealing ring. 5. Inspect cylinder bore and piston
for wear, scuffing or corrosion. Stains and minor corrosion in the cylinder bore may be removed
with crocus
cloth. Thoroughly clean caliper after using crocus cloth.
6. Lubricate cylinder bore and piston square seal, then install piston seal into bore. 7. Install piston
into caliper. 8. Lubricate piston and install dust seal onto piston, then install dust seal onto piston
and caliper.
Service and Repair > Front Caliper > Page 2919
Brake Caliper: Service and Repair Rear Caliper
1. Disconnect brake hose from caliper. 2. Remove parking brake cable as follows:
a. Disconnect rear brake cable from front cable. b. Remove brake cable from cable support
bracket. c. Disconnect brake cable from brake lever.
3. Remove lower slide pin. 4. Remove caliper assembly.
Fig. 1 Rear Caliper Installation
a. Tighten to specifications. b. Push piston into original position by rotating clockwise until it stops,
then set piston, aligning uneven section on piston surface with caliper
center, Fig. 1.
c. Brake pad is equipped with a pinion. The auto-adjuster becomes inoperable when this pinion is
not correctly placed into the indentation of the
piston correctly.
Fig. 4 Rear Caliper, Exploded View

Service and Repair > Front Caliper > Page 2920
Refer to Fig. 4 for rear caliper overhaul.
1. Remove caliper from vehicle. 2. Remove guide pin boot, then the sleeve and sleeve boot. 3.
Remove piston boot ring using small screwdriver. 4. Remove piston dust boot. 5. Insert a piece of
wood into caliper and force piston out by applying compressed air through brake hose opening in
caliper. 6. Remove caliper to piston seal. 7. Remove breather with cap. 8. Reverse procedure to
assemble, installing new guide pin boot, sleeve boot, piston boot ring, piston boot, and caliper
piston seal supplied with
overhaul kit, and note the following: a. Using special rubber grease supplied with rear kit, lubricate
ring seal and cylinder bore. b. When inserting piston into cylinder bore, use finger pressure only. c.
Using special grease, lubricate piston boot before installing into cylinder bore and apply grease to
foot fitting face of piston. d. Fill sleeve boot and guide pin boot with grease before installing on
caliper. e. Install guide pin boot after applying grease into lockpin hole in caliper. f.
Tighten bleeder screw to specification and install cap.

Isuzu Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > IB00-09-S001 > Jul > 00 > Disc Brakes -
Squeal
Brake Pad: All Technical Service Bulletins Disc Brakes - Squeal
BULLETIN NUMBER: IB00-09-S001
GROUP: BRAKES
DISC BRAKE SQUEAL
AFFECTED VEHICLES
All Isuzu Vehicles
SERVICE INFORMATION
Some customers may comment on brake squeal during initial light brake application and at low
speeds. This squeal type sound is caused by a high-frequency vibration of the brake pads against
the rotating brake rotor and is unavoidable due to brake pad and brake rotor friction.
Proper installation of OEM brake hardware and applying anti-seize compound (or equivalent high
temp anti-rattle compound) to the brake pad backing will dampen and reduce this vibration.
However, the level of vibration varies due to outside temperature, humidity, road conditions (mud,
dust and road salt), and brake pad lining condition.
IMPORTANT:
Do not apply anti-seize compound (or equivalent high temp anti-rattle compound) to the brake
lining or rotor. Brake lining contamination will reduce braking efficiency.
If the brake squealing is exceptionally loud, then a brake inspection should be performed. However,
it is always important to confirm the severity of the brake squeal prior to performing any repairs.
This could avoid any misconceptions that customers could develop regarding the operation of their
Isuzu vehicle's brakes.
NOTE:
The customer should be made aware, that some brake squeal may be heard under normal braking
conditions.
Technical Service Bulletins > Customer Interest for Brake Pad: > IB00-09-S001 > Jul > 00 > Disc Brakes - Squeal
Brake Pad: Customer Interest Disc Brakes - Squeal
GROUP: BRAKES
DISC BRAKE SQUEAL
AFFECTED VEHICLES
All Isuzu Vehicles
SERVICE INFORMATION
Some customers may comment on brake squeal during initial light brake application and at low
speeds. This squeal type sound is caused by a high-frequency vibration of the brake pads against
the rotating brake rotor and is unavoidable due to brake pad and brake rotor friction.
Proper installation of OEM brake hardware and applying anti-seize compound (or equivalent high
temp anti-rattle compound) to the brake pad backing will dampen and reduce this vibration.
However, the level of vibration varies due to outside temperature, humidity, road conditions (mud,
dust and road salt), and brake pad lining condition.
IMPORTANT:
Do not apply anti-seize compound (or equivalent high temp anti-rattle compound) to the brake
lining or rotor. Brake lining contamination will reduce braking efficiency.
If the brake squealing is exceptionally loud, then a brake inspection should be performed. However,
it is always important to confirm the severity of the brake squeal prior to performing any repairs.
This could avoid any misconceptions that customers could develop regarding the operation of their
Isuzu vehicle's brakes.
NOTE:
The customer should be made aware, that some brake squeal may be heard under normal braking
conditions.
Service and Repair > Front Pads
Brake Pad: Service and Repair Front Pads
REMOVAL
1. Raise vehicle and remove wheel assembly. 2. Remove lock bolt from caliper. 3. Position caliper
upward, then remove shoe, lining assemblies and shims. Mark lining locations if linings are to be
reinstalled. 4. Remove shoe clips from support.
INSTALLATION
If original linings are being installed, they must be installed in the original position as marked during
removal.
1. Lubricate shims, then install new shoe clips, shims, shoe and lining assemblies to support.
During installation of linings to the support, position
wear indicators to lower side of support.
2. Lower caliper into position and install lock bolt to caliper. 3. Install wheel assembly and lower
vehicle.
Service and Repair > Front Pads > Page 2936
Brake Pad: Service and Repair Rear Pads
1. Remove wheel and tire assembly, then secure rotor with wheel nuts. 2. Remove lower slide pin.
Lift caliper up and support with wire. 3. Remove pad and shim. 4. Remove retaining clips. 5.
Reverse procedure to install. Tighten to specifications.
Isuzu Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Brake Rotor Dimensions
Brake Rotor/Disc: Specifications Brake Rotor Dimensions
Nominal Thickness 1.02 in
Minimum Refinish Thickness 0.983 in
Thickness Variation (Parallelism) 0.0004 in
Lateral Runout (T.I.R.) 0.005 in
Nominal Thickness 0.710 in
Minimum Refinish Thickness 0.668 in
Thickness Variation (Parallelism) 0.0004 in
Lateral Runout (T.I.R.) 0.005 in

> Specifications > Brake Rotor Dimensions > Page 2941
Brake Rotor/Disc: Specifications
Disc to hub retaining bolts 103 Nm (76 ft.lbs.)

> Service and Repair > Front Brake Rotor
Brake Rotor/Disc: Service and Repair Front Brake Rotor
With Automatic Locking Hub
FRONT HUB AND DISC (4WD Model with Automatic Locking Hub)
REMOVAL
meter.
1. Bolt
Remove the 14 mm hex bolts.
Lockwasher
> Service and Repair > Front Brake Rotor > Page 2944
8. Hub nut
Wrench: J-36827
9. Remove the caliper, then the hub and disc assembly.
- Remove the two bolts from the brake caliper. Remove the caliper with the brake hose attached.
- Use a wire to attach the brake caliper to the frame.
10. Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disc-to-hub
retaining bolts.
INSTALLATION
1. Attach the hub to the disc.
Tighten the bolts to the specified torque.
Torque: 103 N.m (76 lb.ft.)
a) Put grease in the hub. b) Apply Besco L-2 or equivalent to the seal lip and outer and inner
bearing and if removed.
3. Hub nut
Wrench: J-36827
Preload adjustment -
Tighten the hub nut at 29.4 N.m (21.7 lb.ft), then loosen the nut to the full.
- Tighten the hub nut at the value given above, using a spring scale on the wheel pin.
- If the measured bearing preload is outside the specifications, adjust it by loosening or tightening
the bearing nut.
4. Lock washer
washer.
- If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse
the lock plate.
- If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. Screw is
to be fastened tightly so its head may come lower than the surface of the washer.
5. Inner cam
a) Before installation, shift the transfer lever to "2H" position.
b) Clean the flange surface of the hub, the thread holes, the surface of the lock washer and the
c) Install the inner cam by aligning the key way of the inner cam with the groove of the knuckle.
surface as shown in the illustration. Installer : J-38194
a) Apply specified grease to the axle shaft splines and inner surfaces of the drive hub. b) Align the
cut portion of the drive clutch assembly with the concave portion of inner cam. c) Engage the cam
teeth of the drive clutch assembly to that of the inner cam by turning the axle shaft.
a) Install shims to axle by hand.
b) Install special tool J-36835-2 to axle. c) Install snap ring to tool. d) Install tool driver J-36835-1.
e) Pull out the axle shaft fully by pulling the tool J-36835-2. Install snap ring to axle by pushing on
tool driver J-36835-1. f) Remove tool driver J-36835-2 from axle.
8. Housing assembly 9. Hubcap
10. Bolt
a) Apply Loctite 515 (or the equivalent) to the flange surface of the housing assembly. b) Make
sure that the housing assembly turns smoothly. If it turns smoothly, the spacer is correct. c) Tighten
the bolt to the specified torque.
11. Reinstall brake caliper.
With Manual Locking Hub
FRONT HUB AND DISC (4WD Model with Manual Locking Hub)
REMOVAL
Before removal, shift transfer lever into "2H" position ?nd set free wheeling hub knob into "FREE"
position.
1. Remove the two bolts from the brake caliper. Remove the caliper with the brake hose attached.
2. Use a wire to attach the brake caliper to the frame. 3. Remove the housing assembly, snap ring
and shims, body assembly and lock washer.
4. Remove the hub nut using Wrench: J-36827. 5. Hub and disc assembly 6. Clamp hub and disc
assembly in vise, using protective pads. Remove six (6) disc- to-hub retaining bolts.
INSTALLATION
1. Install hub to disc
Tighten the bolts to the specified torque.
2. Install the hub and disc assembly, then the hub nut.
Wrench: J-36827
Preload adjustment
- Tighten the hub nut to 29.4 Nm (21.7 lb. ft.), then fully loosen the nut.
- Tighten the hub nut to the value given below, using a spring scale on the wheel pin.
^ If the measured bearing preload is outside the specifications, adjust it by loosening or tightening
the bearing nut.
3. Lock washer
washer.
- IF bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the
lock plate.
- If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. Screw is
to be fastened tightly so its head may come lower than the surface of the washer.
4. Body assembly
- Apply adhesive (Loctite 515 or equivalent) to both joining faces.
- Tighten the bolts to the specified torque.

- Adjust the clearance between the free wheeling hub body and the snap ring.
6. Housing assembly
- Align stopper nails to grooves of body.
7. Bolt
- Tighten the bolts to the specified torque.
8. Reinstall brake caliper and wheel.

Brake Rotor/Disc: Service and Repair Rear Brake Rotor
1. Raise and support vehicle so that rear wheels rotate freely, then remove rear wheels. 2. Remove
brake pads as outlined under Brake Pad Service. 3. Remove caliper and caliper frame assembly as
an assembly. Release emergency brake cable from support as required. Do not allow caliper to
hang from brake hose.
4. Slide rotor off hub. 5. Reverse procedure to install, noting the following:
a. Thoroughly clean the hub area before installing the rotor. b. Tighten bolts to specifications.
Isuzu Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications
Brake Drum: Specifications
Drum Brake Inside Diameter 10.000 in
Maximum Refinish Diameter 10.059 in

Isuzu Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair
Brake Shoe: Service and Repair
Brake Lining Replacement
Refer to Fig. 1. for brake shoe replacement.

Isuzu Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Specifications > Tightening Torque
Wheel Cylinder: Specifications
Bleeder Screw 5.5 in.lb
Brake Line To Wheel Cylinder 9-14 in.lb
Wheel Cylinder To Backing Plate 6-9 in.lb

Isuzu Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Specifications > Tightening Torque > Page 2963
Wheel Cylinder Bore Diameter 0.875 in

Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
ventilated.

Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Caliper Bore Diameter
Brake Caliper: Specifications
Front Caliper Bore Dia. 2.375 in

Information > Specifications > Caliper Bore Diameter > Page 2972
Brake Caliper: Specifications Torque Specifications
Caliper Guide Pin Bolt 54 ft.lb
Flexible Brake Hose To Brake Line 12 ft.lb
Flexible Brake Hose To Caliper 26 ft.lb
Caliper Bracket 69-84 ft.lb
Caliper Slide Pin Lock Bolt 121-17 ft.lb
Bleeder Screw 6 ft.lb
Caliper Slide Pin Lock Bolt 32 ft.lb

Information > Service and Repair > Front Caliper
Brake Caliper: Service and Repair Front Caliper
Removal
1. Perform steps one through three as outlined under Brake Pad Service And Repair procedure.
See: Disc Brake System/Brake Pad/Service and
Repair
2. Disconnect brake hose from caliper and cap openings in hose and caliper. 3. Remove caliper
from vehicle.
Installation
1. Perform steps one through three as outlined under Brake Pad Service And Repair installation
procedure. See: Disc Brake System/Brake
Pad/Service and Repair
2. Connect brake hose to caliper, then bleed brake system. 3. Install wheel assembly and lower
vehicle.
Fig. 2 Front Caliper, Exploded View
Refer to Fig. 2 for front caliper overhaul.
1. Remove guide and lock bolts from caliper. 2. Remove dust seal from caliper with a small
screwdriver. 3. Place a block of wood into caliper and force piston from caliper with compressed air
applied to the fluid port. 4. Remove piston square sealing ring. 5. Inspect cylinder bore and piston
for wear, scuffing or corrosion. Stains and minor corrosion in the cylinder bore may be removed
with crocus
cloth. Thoroughly clean caliper after using crocus cloth.
6. Lubricate cylinder bore and piston square seal, then install piston seal into bore. 7. Install piston
into caliper. 8. Lubricate piston and install dust seal onto piston, then install dust seal onto piston
and caliper.
Information > Service and Repair > Front Caliper > Page 2975
Brake Caliper: Service and Repair Rear Caliper
1. Disconnect brake hose from caliper. 2. Remove parking brake cable as follows:
a. Disconnect rear brake cable from front cable. b. Remove brake cable from cable support
bracket. c. Disconnect brake cable from brake lever.
3. Remove lower slide pin. 4. Remove caliper assembly.
Fig. 1 Rear Caliper Installation
a. Tighten to specifications. b. Push piston into original position by rotating clockwise until it stops,
then set piston, aligning uneven section on piston surface with caliper
center, Fig. 1.
c. Brake pad is equipped with a pinion. The auto-adjuster becomes inoperable when this pinion is
not correctly placed into the indentation of the
piston correctly.
Fig. 4 Rear Caliper, Exploded View

Information > Service and Repair > Front Caliper > Page 2976
Refer to Fig. 4 for rear caliper overhaul.
1. Remove caliper from vehicle. 2. Remove guide pin boot, then the sleeve and sleeve boot. 3.
Remove piston boot ring using small screwdriver. 4. Remove piston dust boot. 5. Insert a piece of
wood into caliper and force piston out by applying compressed air through brake hose opening in
caliper. 6. Remove caliper to piston seal. 7. Remove breather with cap. 8. Reverse procedure to
assemble, installing new guide pin boot, sleeve boot, piston boot ring, piston boot, and caliper
piston seal supplied with
overhaul kit, and note the following: a. Using special rubber grease supplied with rear kit, lubricate
ring seal and cylinder bore. b. When inserting piston into cylinder bore, use finger pressure only. c.
Using special grease, lubricate piston boot before installing into cylinder bore and apply grease to
foot fitting face of piston. d. Fill sleeve boot and guide pin boot with grease before installing on
caliper. e. Install guide pin boot after applying grease into lockpin hole in caliper. f.
Tighten bleeder screw to specification and install cap.

Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Brake Fluid: Specifications
Fluid Type DOT 3 or 4

Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Isolation/Dump Valve <--> [Brake
Fluid Accumulator] > Component Information > Service and Repair
Isolation/Dump Valve: Service and Repair
1. Raise and support vehicle. 2. Disconnect harness connector. 3. Disconnect brake lines from
valve assembly. 4. Remove isolation/dump valve retaining bolts, then valve assembly from vehicle.
a. Torque isolation valve retaining bolts to 18 ft. lbs. b. Torque brake line flare nuts to 12 ft. lbs. c.
Bleed brake system.
Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Hose
Brake Hose/Line: Service and Repair Brake Hose
BRAKE HOSE REPLACEMENT
Brake Hose Replacement
REMOVAL
^ Raise the vehicle and support it with suitable safety stands. ^ Remove wheel and tire assembly. ^
Clean dirt, grease, and other foreign material off the hose fittings at both ends.
INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points. After installing
the brake hoses, bleed brakes.
NOTE: Always use new copper gaskets.
Front Brake Hose 1. Tighten the brake pipes to the specified torque.
2. Tighten the bolt to the specified torque.
Torque: 35 Nm (26 lb.ft.)
Rear Brake Hose 1. Tighten the brake pipes to the specified torque.
2. Tighten the bolt to the specified torque.

Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Hose > Page 2990
Brake Hose/Line: Service and Repair Brake Pipe
BRAKE PIPE REPLACEMENT
Brake Pipe Components
REMOVAL
^ Raise the vehicle and support it with suitable safety stands. ^ Remove wheel and tire assembly. ^
Clean dirt, grease, and other foreign material off the pipe fittings at both ends.
INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points. After installing
the brake pipes, bleed brakes.
1. Tighten the brake pipes to the specified torque.

Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation
Brake Proportioning/Combination Valve: Description and Operation
The combination valve contains two separate sections, each serving a different function. The
proportioning section of the combination valve proportions outlet pressure to the rear brakes after a
predetermined rear input pressure has been reached. This is done to prevent rear wheel lock-up on
vehicles with light rear wheel loads.
These valve(s) which are threaded into the master cylinder (standard brake system), limit outlet
pressure to the rear brakes after a predetermined master cylinder pressure has been reached. This
is used when less rear apply force is needed to obtain optimum braking.
The valve has a ``bypass'' feature which assures full system pressure to the rear brakes, in the
event of a front brake system malfunction, also full front pressure is retained in the event of rear
malfunction.
The pressure differential warning switch is designed to constantly compare front and rear brake
pressure from the master cylinder and turn on the brake system warning light on the instrument
panel, in the event of a front or rear system malfunction. The valve and switch are designed to the
switch will latch in the ``warning'' position once a malfunction has occurred. The only way the light
can be turned off is to repair the malfunction and apply a pedal force required to develop line
pressure.
Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Brake Master Cylinder: Specifications
Master Cylinder Bore Dia., Inch ...........................................................................................................

........................................................................ 1.000
Information > Description and Operation > Diagonal Split Master Cylinder
Brake Master Cylinder: Description and Operation Diagonal Split Master Cylinder
The diagonal split master cylinder incorporates the functions of the standard dual master cylinder
plus a fluid level sensor and proportioning valves. In a diagonal split system, the left rear brake and
the right front brake are on the same hydraulic circuit in the master cylinder. The left front brake
and right rear brake are also on the same circuit in the master cylinder.
Information > Description and Operation > Diagonal Split Master Cylinder > Page 2999
Brake Master Cylinder: Description and Operation Dual Master Cylinder
The master cylinder contains two pistons that supply hydraulic pressure for a dual-circuit brake
system. The primary piston provides the fluid pressure to the front brakes, while the secondary
piston provides the fluid pressure to the rear brakes. If the pressure is lost from either system, the
remaining system will function to stop the vehicle.
Brake Master Cylinder: Service and Repair
1. Disconnect brake lines from master cylinder. Plug lines to prevent contamination. 2. Remove
master cylinder-to-power brake unit retaining nuts, then lift master cylinder from engine
compartment. 3. Reverse procedure to install. Torque master cylinder retaining nuts to 8-11 ft. lbs.
and brake line fittings to 11 ft. lbs.
Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Tightening Torque
Bleeder Screw 5.5 in.lb
Brake Line To Wheel Cylinder 9-14 in.lb
Wheel Cylinder To Backing Plate 6-9 in.lb

Isuzu Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Tightening Torque > Page 3005
Wheel Cylinder Bore Diameter 0.875 in

Isuzu Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Adjustments
Parking Brake Cable: Adjustments
PARKING BRAKE ADJUSTMENT
NOTE: ^
All brakes are self-adjusting. Brakes are adjusted by repeated stepping on the brake pedal. (After
stepping on the pedal and releasing it, the rear auto-adjuster, in the rear brake, produces a clicking
sound. The same operation should be repeated until the sound disappears.)
^ Periodically check that the parking brake lever travel is between 9 and 11 notches.
^ Take the following steps if the parking brake lever traveling range deviates from the specified
notch numbers (9-11 notches), or after overhauling the rear brake assembly.
1. Move the parking brake handle to its fully released position.
2. Parking cable must be loosed sufficiently. (Loosen the adjust nut and the lock nut.) 3. Repeat
stepping on the brake pedal firmly, and releasing it until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter and diameter of the brake shoes is
adjusted to be 0.5mm, the number of times for depressing the brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside diameter and diameter of the brake shoes.
Shoe clearance: 0.25 - 0.40 mm (0.0098 - 0.0157 in.)
If incorrect, check the brake auto-adjusting system.
5. Firmly grasp the second relay lever rod. Rotate the adjust nut until all slack disappears from the
cable. Set the adjust nut. 6. Applying about 30 kg (66 lb.) of force, pull the parking brake handle to
its fully set position three or four times. 7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully engaged position will be between 9 and 11
notches.
- If the travel is not within these limits, again repeat steps 1 through 5.
- After adjusting has been done, check to see if the rear wheel rotates smoothly without drag when
turned by hand.
Information > Adjustments > Page 3010
Parking Brake Cable: Service and Repair
CABLE REPLACEMENT
REMOVAL
^ Raise the vehicle and support it with suitable safety stands. ^ Remove rear wheel and tire
assemblies.
Cable assembly; rear ^ Remove rear brake shoe assemblies.
Compressing Locking Lugs On Cable With Offset Box Wrench
^ Use offset box wrench (13 mm hex.) to compress the locking lugs on the cable, then remove the
cable from the Backing plate.
INSTALLATION NOTES
1. 1st relay lever assembly

- Apply grease (BESCO L-2 or equivalent) to the inner and outer surface of the bushes and cable
connecting portion.
- Tighten the nut to the specified torque.
2. 2nd relay lever assembly
- Apply grease (BESCO L-2 or equivalent) to the arrowed portion in figure above
3. Intermediate cable
- After applying grease (BESCO L-2 or equivalent) to the cable guide, set it to the bracket by
striking lightly with a mallet.
- Apply grease(BESCO L-2 or equivalent) to the arrowed portion in figure above.
4. Split pin with plane washer
- Discard the used split pin and use new parts.
5. Adjust parking brake.

Isuzu Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation > Single Vacuum Unit
Vacuum Brake Booster: Description and Operation Single Vacuum Unit
In a normal operating mode, with the service brakes in the released position, the single vacuum
booster operates with vacuum on one side of the diaphragm. When the brakes are applied, air at
atmospheric pressure is admitted to one side of the diaphragm to provide the power assist. When
the service brake is released, the atmospheric pressure is cut off from the one side of the
diaphragm. The air is then drawn from the booster through the vacuum check valve to the vacuum
source.
Information > Description and Operation > Single Vacuum Unit > Page 3018
Vacuum Brake Booster: Description and Operation Tandem Vacuum Unit
In a normal operating mode, with the service brakes in the released position, a tandem vacuum
booster operates with vacuum on both sides of its diaphragms. When the brakes are applied, air at
atmospheric pressure is admitted to one side of each diaphragm to provide the power assist.
Vacuum Brake Booster: Service and Repair
1. Disconnect brake lines and remove master cylinder. 2. Remove clamp and disconnect vacuum
hose from booster.
Fig. 5 Power Brake Unit Replacement
3. Remove instrument panel undercover (4), and vent duct (5), Fig. 5. 4. Disconnect return spring
from brake pedal, then remove snap pin and booster rod pin. 5. Loosen power booster mounting
nuts, then remove booster from vehicle. 6. Reverse procedure to install, noting the following:
a. Apply 19.7 inch Hg of negative pressure to vacuum booster, then adjust pushrod length to .717
inch, if necessary.
b. Torque booster mounting nuts to 16 ft. lbs. c. Apply grease to entire surface of booster rod pin
(8), Fig. 5. d. Ensure pedal return height is 6.85-7.24 inches.
OVERHAUL
The vacuum boosters cannot be disassembled for repair. Service is available only through
replacement.
Isuzu Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Brake Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3026

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair



Brake Control Module > Component Information > Diagrams > Page 3048
Isuzu Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Description and Operation
Isuzu Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair
lbs.
Isuzu Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
9305011 > Jun > 93 > A/T Mode Switch - No Crank In Neutral Position
Position
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
references.

Step 3.

ground (Figure 3).

PARTS INFORMATION

93 > A/T Mode Switch - No Crank In Neutral Position
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
references.

Step 3.

ground (Figure 3).

PARTS INFORMATION

Isuzu Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Testing and Inspection
Battery: Technical Service Bulletins Battery - Testing and Inspection
GROUP ELECTRICAL
BATTERY TEST AND CHARGE
VEHICLES AFFECTED
All Isuzu models.
SERVICE INFORMATION
Many batteries that are replaced because of poor performance are later found (during warranty
inspection) to have no defects. This Service Bulletin describes proper battery testing and charging
procedures which must be completed before a battery is replaced. All technical readings must be
recorded on the warranty repair order.
SERVICE PROCEDURE
WARNING
Keep battery away from open flame, as hydrogen gas generated by battery is highly flammable.
Wear safety glasses when working near batteries. In case of skin contact with battery acid, flush
affected area immediately with water.
CAUTION
Charge battery only when battery temperature is below 60 degrees C (140 degrees F). If battery
temperature rises above this temperature, stop charging procedure.
1. Put voltmeter test leads to battery terminals.
a. If battery voltage is 12.4 V or above, load test battery as described in Step 3 of this procedure.
b. If battery voltage is under 12.4 V, fast charge battery as described in Step 2 before performing
load test.
2. Determine fast charge amperage (Figure 1). Fast charge battery for 30 minutes at amperage
rate no higher than specified in Figure 1. Take voltage reading after charge.
a. If voltage is above 16 V, replace battery.
b. If voltage is between 12 V and 16 V, continue charging at the same rate for an additional 3-1/2
hours.
c. Perform load test as described below.
3. Load test battery as follows. This procedure is based on the Sun VAT 40 starting/charging
system tester check the manufacturer's operating instructions if using a different machine.
a. Set tester LOAD CONTROL and FUNCTION SELECTOR knobs to OFF.
b. Connect red clamp of tester lead to POSITIVE battery terminal.
c. Connect black clamp of tester lead to NEGATIVE battery terminal.
d. Attach inductive amp probe around red test cable. Arrow on probe must be facing the battery.
e. Remove surface charge from battery.
f. Set FUNCTION SELECTOR knob to BATTERY LOAD TEST.
g. Set LOAD CONTROL knob to the appropriate test load amperage. (See Figure 1.)
Isuzu Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Battery - Testing and Inspection > Page 3083
h. Wait approximately 15 seconds, then compare the voltage reading to the appropriate voltage
specified in Figure 2.
i. If battery fails load test after fast charge, perform slow charge as described in Step 4.
4. Performs slow charge by charging battery for 24 hours at a rate not over 3 amperes. After slow
charge, load test battery again. If battery fails load test after slow charge, replace battery.
Isuzu Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component
Generator: Electrical Specifications
Model No. 100211-7990
Rated Hot Output, Amps .....................................................................................................................

..................................................................... 75
Model No. 100211-8990

..................................................................... 90
Model No. 100211-9730

..................................................................... 75
Model No. 101211-0160

..................................................................... 75
Model No. 101211-2020

..................................................................... 60
Generator: Mechanical Specifications
Alternator Belt
New Belt Tension, Lbs. ........................................................................................................................

.......................................................... 100-140
Air Conditioning Belt

.......................................................... 100-140
Power Steering Belt

............................................................ 70-110
Generator: Testing and Inspection
Fig. 4 Alternator Test Connections

To check alternator in a test stand, proceed as follows:
1. Connect alternator as shown in Fig. 4, except leave carbon pile disconnected. The ground
polarity of the alternator and the battery must be the
same. The battery must be fully charged. Use a 30-500 ohm resistor between battery and ``L''
terminal.
2. Slowly increase alternator speed and observe voltage. 3. If the voltage is uncontrolled and
increases above 16.0 volts, the rotor field is shorted or grounded or the regulator is defective, or
both. A
defective rotor field coil can cause the regulator to become defective. The battery must be fully
charged when making this test.
4. If voltage is below 16.0 volts, increase speed and adjust carbon pile to obtain maximum amperes
output. Maintain voltage above 13.0 volts. 5. If output is within 15 amperes of rated output the
alternator is good. 6. If output is not within 15 amperes of rated output, alternator is defective and
requires replacement.
Isuzu Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode
Switch - No Crank In Neutral Position
Position
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
references.

Switch - No Crank In Neutral Position > Page 3100
Step 3.

ground (Figure 3).

PARTS INFORMATION

Technical Service Bulletins > Customer Interest for Neutral Safety Switch: > 9305011 > Jun > 93 > A/T Mode Switch - No
Crank In Neutral Position
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
references.

Crank In Neutral Position > Page 3109
Step 3.

ground (Figure 3).

PARTS INFORMATION

Isuzu Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications
Starter Motor: Specifications
Model No. ............................................................................................................................................

................................................................ GD002350 Rotation ............................................................
..............................................................................................................................................................
. [01] No Load Test:
Amperes (Max.) ...................................................................................................................................

.................................................................... 90 Volts ...........................................................................
.............................................................................................................................................. 11 RPM
(Min.) ...................................................................................................................................................
....................................................... 2700
Load/Torque Test:
Amperes (Max.) ...................................................................................................................................

.................................................................. 250 Volts ...........................................................................
............................................................................................................................................. 8.4
Torque Ft. Lbs. (Min.) ..........................................................................................................................
..................................................................... 4
[01] -- Clockwise when viewed from pinion side.

Isuzu Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Starter Motor: Service and Repair
REMOVAL
1. Remove the negative battery cable. 2. Remove pre-catalytic converter fixing bolts and
pre-catalytic converter. 3. Remove exhaust pipe, (front left). 4. Remove heat protector. 5.
Disconnect the starter wiring connector from terminals "B" and "S". 6. Remove mounting bolts on
inside and out-side. 7. Remove the starter assembly toward the bottom of engine.
INSTALLATION
1. Install the starter assembly. 2. Install the starter mounting bolts. Torque to 40 Nm (30 lb.ft.). 3.
Reconnect the starter wiring connectors to terminals "B" and "S". Torque to 8.5 Nm (73 lb.in.). 4.
Install the Heat protector. 5. Install the Exhaust pipe, (front left). Torque nuts to 67 Nm (49 lb.ft.). 6.
Install the Pre-catalytic converter fixing bolts. Torque to 27 Nm (20 lb.ft.).
Isuzu Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing
and Inspection
Starter Solenoid: Testing and Inspection
Complete each test within three to five seconds. If time limit is exceeded, possible damage to the
starter solenoid may result.
PULL-IN TEST:
1. Connect the battery negative terminal with the solenoid switch body and the C terminal. When
current is applied to the terminal as shown in Fig. 5
from the battery positive terminal, the pinion should flutter.
HOLD-IN MAINTENANCE TEST:
21. Disconnect the lead at the C terminal as shown in Fig. 6. The pinion should continue to flutter.
RETURN TEST:
Isuzu Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing
and Inspection > Page 3120
1. Connect the battery ground terminal to the 50 terminal and the body as shown in Fig. 7. 2.
Connect the battery positive terminal to the C terminal. The pinion will flutter. 3. When the lead to
the 50 terminal is disconnected, the pinion should immediately return to its stationary position. 4. If
the pinion does not operate as specified, repair or replace starter motor as necessary.
Isuzu Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations
Dash Fuse Box

Isuzu Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
> Diagrams > Diagram Information and Instructions > Page 3129

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair







Isuzu Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations
Dash Fuse Box

Isuzu Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair







Isuzu Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Front End Alignment - Inspection (Manual Revision)
Alignment: Technical Service Bulletins Front End Alignment - Inspection (Manual Revision)
GROUP: SUSPENSION
1992-98 TROOPER (UX), 1991-97 RODEO (UC), 1998 RODEO (UE) FRONT END ALIGNMENT
INSPECTION (Workshop Manual Revision)
AFFECTED VEHICLES
1992-98 Trooper (UX), 1991-97 Rodeo (UC), 1998 Rodeo (UE) models.
SERVICE INFORMATION
Front End Alignment - Inspection (Manual Revision) > Page 3194
The inspection procedure contained in Section 3A - Front End Alignment (1992-97 Trooper,
1991-97 Rodeo) and in Section 2A - Power Assisted Steering System (1998 Trooper and 1998
Rodeo) of the listed Workshop Manuals, has been revised.
The front end inspection procedure has been revised to include steps to ensure that the vehicle is
in an unladen condition (no passengers no loading) and that the spare tire is installed in its normal
position.
pages.
Isuzu Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Wheel
Alignment
Alignment: Specifications Front Wheel Alignment
Caster Angle, Degrees:
Limits ...................................................................................................................................................
.......................................... +1 7/12 to +3 1/12 Desired .......................................................................
........................................................................................................................................ +2 1/3
Camber Angle, Degrees:
Limits ...................................................................................................................................................
................................................... -1/2 to +1 1/2 Desired ......................................................................
........................................................................................................................................... + 1/2
Toe-In, Inch [01] ..................................................................................................................................

.................................................................... 0 to +.16 King Pin Inclination, Degrees ..........................
..............................................................................................................................................................
.... 10 Knuckle Angle At Full Lock, Degrees:
Inside ...................................................................................................................................................
.................................................................. [02] Outside ......................................................................
............................................................................................................................................ [03]
[01] -- Toe-in (+); toe-out (-). [02] -- With 10.5R tires, 32 degrees; less 10.5 tires, 35 degrees. [03] --
With 10.5R tires, 29 degrees; less 10.5 tires, 33 degrees.
Isuzu Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Wheel
Alignment > Page 3203
Alignment: Specifications Rear Wheel Alignment
This model has a solid rear axle. No specifications exist for Camber or Toe-in.
Isuzu Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Front
Suspension
Alignment: Service and Repair Front Suspension
Caster & Camber
Fig. 1 Caster angle adjustment
Fig. 2 Camber angle adjustment
Caster angle can be adjusted with caster shims installed in position between the chassis frame and
the fulcrum pins, Fig. 1. Camber angle can be adjusted with the shims installed in position between
the chassis frame and the fulcrum pins, Fig. 2.
Toe-In
To adjust toe-in angle, loosen locknut on the outer track rod and turn outer track rod with the same
degree as right and left, Fig. 3.
Suspension > Page 3206
Alignment: Service and Repair Trim Height
Trim Height Inspection Procedure
Before making any wheel alignment adjustments, inspect the following:
1. Tires for proper inflation pressure. 2. Front wheel bearing for proper adjustment. 3. Ball joints, tie
rod ends and relay rods for excessive looseness. 4. Wheels and tires for run out. 5. Vehicle trim
height. If not within specifications, trim height must be corrected before adjusting caster. 6. Steering
gear for looseness at frame. 7. Shock absorbers for leaks or any noticeable noise. 8. Control arms
or stabilizer bar attachment for looseness.
Suspension > Page 3207
Alignment: Service and Repair Vehicle Ride Height
Vehicle height is adjusted by an adjusting bolt on the control arms. Before adjusting trim height,
check tire pressure and ensure vehicle is on level ground.
Fig. 5 Ride height measurement points. 4WD models
1. Measure vehicle ride height as shown in Fig. 5. 2. Subtract measurement (A) from measurement
(B) to find vehicle ride height specification. 3. Turn adjustment bolt as necessary. Dimension (Z)
should be 4.96 inches.
Isuzu Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Specifications
Pressure ..............................................................................................................................................
Low pressure .......................................................................................................................................

........................................................................................................................................................
continuity

PURPOSE
LOCATION
OPERATION
PSP Switch Circuit
Circuit Description
de-energized.
Test Description

Isuzu Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Mark positions of torsion
bar adjusting bolt, front and rear positions of torsion bar for correct installation. 3. Loosen torsion
bar adjusting bolt, then remove hub center cover assembly. 4. Remove snap ring and shims from
hub. 5. Remove brake caliper and support with wire out of way. 6. Using removal tool No. J-29107,
or equivalent, remove tie rod end from steering knuckle. 7. Remove upper and lower cotter pins,
then ball joint retaining nuts. 8. Using removal tool No. J-29107, or equivalent, separate ball joints
from steering knuckle. 9. Remove steering knuckle from vehicle.
10. Reverse procedure to install.

Isuzu Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Power Steering Bleeding: Service and Repair

Fig. 1 Power Steering System Bleeding Procedure.
Refer to Fig. 1 for power steering system bleeding procedure.

Isuzu Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Power Steering Fluid: Technical Service Bulletins Dexron-IIE Fluid - Recommended Usage
GROUP MISCELLANEOUS
AFFECTED VEHICLES
SERVICE INFORMATION

Isuzu Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Power Steering Fluid: Specifications
GENERAL SPECIFICATIONS
Fluid Type ............................................................................................................................................

................................................... Dexron-II E ATF
Isuzu Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Power Steering Pump: Specifications
Alternator Belt

.......................................................... 100-140
Air Conditioning Belt

.......................................................... 100-140
Power Steering Belt

............................................................ 70-110
Isuzu Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Power Steering Pump: Service and Repair
1. Disconnect power steering hoses at pump.
2. Remove drive belt.
3. Remove power pump to mounting bracket bolts, then remove pump.

Isuzu Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Specifications
Pressure ..............................................................................................................................................
Low pressure .......................................................................................................................................

........................................................................................................................................................
continuity
Pressure Switch > Component Information > Specifications > Page 3238

PURPOSE
LOCATION
OPERATION
PSP Switch Circuit
Circuit Description
de-energized.
Test Description

Isuzu Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping
Undeployed Air Bag
System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 3247

LAW.
Deployed Air Bag
total particulate.
result.
diagnose.
System Information > Service Precautions > Page 3252
PRECAUTIONS
signs of damage.
Isuzu Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Manual Steering Gear
Steering Gear: Service and Repair Manual Steering Gear
1. Disconnect stabilizer bar, if necessary, then remove steering shaft nut.
2. Disconnect pitman arm using a suitable puller, then scribe locating marks on coupling flange and
worm shaft for reassembly.
3. Remove coupling clamp bolt, gearbox mounting bolts, then the gearbox.
Disassembly and Assembly
DISASSEMBLY
Repair > Manual Steering Gear > Page 3257
Fig. 1 Exploded View Of Manual Steering Gear Assembly
1. Drain lubricant from gearbox through filler plug hole, Fig. 1. 2. Clamp steering gear in a suitable
vise. 3. Remove adjust screw locknut, turn adjust screw counterclockwise removing sector gear
and ball nut rack preload. Remove top cover bolts.
Fig. 2 Gearbox Top Cover Removal
4. Hold the top cover stationary while turning the adjust screw clockwise to raise and free the
cover, then remove the cover, Fig. 2.
Fig. 3 Selector Shaft Removal
5. Bring worm shaft into straight ahead position and remove top cover and sector shaft from the
gearbox, Fig. 3. Hold the sector shaft in straight
ahead position when removing from gearbox. Do not drive the sector shaft out with a hammer or
other impact tools.
Fig. 4 End Cover Locknut Removal
6. Using locknut removal tool No. J-29753, or equivalent, loosen the locknut securing the end
cover, Fig. 4.
Fig. 5 End Cover Removal
7. Using removal tool No. J-7624, or equivalent, remove end cover, Fig. 5.
Fig. 6 Ball Screw & Nut Assembly Replacement
8. Remove the ball screw and nut assembly from the gearbox, Fig. 6. Remove the lower bearing.
Keep worm and ball nut assembly in horizontal
position. Avoid holding vertically, as ball nut will fall onto end of worm gear and cause damage to
ball tubes.
ASSEMBLY
1. Inspect and replace seals if necessary. 2. Install lower bearing and ball screw and nut assembly
into gearbox, keeping it horizontal. Apply gear oil to the bearings, Fig. 6.
Fig. 7 Worm Shaft Bearing Preload Measurement
3. Clean end cover and gearbox mating surfaces and fit new O-ring into the cover. Apply gear oil to
oil seal and O-ring. Fit the cover over the worm
shaft, being careful not to damage the seal (taping the worm shaft spline may help). Screw in the
end cover, until torque required to rotate the worm shaft is 1.64-5.15 inch lbs., Fig. 7.
Fig. 8 End Cover Locknut Installation
4. Install and tighten locknut to specifications, Fig. 8.

Fig. 9 Sector Shaft Endplay Measurement
5. Install the adjust screw with adjusting shim into sector shaft T slot. Check that no clearance is
provided between the adjust screw head and sector
shaft and the adjust screw slides freely in the slot. If the adjust screw and sector shaft clearance is
in excess of .004 inch, it must be adjusted by means of shims, Fig. 9. Shims are available in the
following sizes: 0.0596-0.0604 inch, 0.060-0.0616 inch, 0.0620-0.0627 inch, 0.0631-0.0639 inch
and 0.0643-0.0651 inch. When reassembling the adjusting shim, turn the face of the shim with
chamfer on the inner edge to the adjust screw head. Apply grease to the T slot in the sector shaft,
before reassembling the adjust screw.
Fig. 10 Sector Shaft Installation
6. Apply grease to the bushing and oil seal in the gearbox. Install the sector shaft as shown in Fig.
10. 7. Apply a suitable sealing compound to gearbox top cover mounting surface and to thread
holes. Install gasket in top cover. 8. Thread the adjust screw into top cover turning the screw
counterclockwise until the top cover contacts the gearbox, continue turning for two or
more turns and install the bolts and washers. Tighten bolts to specification.
9. Holding the relative parts in a straight ahead position, rotate the worm shaft with an inch-pound
wrench. Adjustment of backlash is made by
turning in the adjust screw, so that starting torque checked at straight ahead position is 4.3-8.7 inch
lbs. Tighten adjust screw locknut.
10. Install pitman arm. Tighten bolts to specification. 11. Install coupling on the worm. Tighten bolts
to specification. 12. Add 7 oz. of GL-5 lubricant to gearbox.
Inspection After Removal
1. Clean all parts in solvent and air dry. 2. Inspect steering shaft for bending and serrated portions
for wear or damage. 3. Check ball nut teeth for wear, dents or pitting. 4. Check bearing for wear or
damage. The complete worm and ball nut assembly should be replaced with a new assembly if any
worm shaft
parts are found to be defective.
5. Position worm and ball nut in a vertical position and check that ball nut lowers in a smooth,
twisting, turning motion. Replace entire steering
shaft assembly if turning motion of ball nut is not smooth, or if ball nut is noisy as it lowers.
6. Check sector shaft for any of the following conditions, and replace parts if any of the conditions
are noticeable.
a. Serrated portion is damaged. b. Teeth on sector shaft are worn or damaged.

Steering Gear: Service and Repair Power Steering Gear
1. On models with power steering, disconnect pressure lines.
2. Disconnect stabilizer bar, if necessary, then remove steering shaft nut.
3. Disconnect pitman arm using a suitable puller, then scribe locating marks on coupling flange and
worm shaft for reassembly.
4. Remove coupling clamp bolt, gearbox mounting bolts, then the gearbox.
Disassembly and Assembly

Fig. 2 Exploded View Of Power Steering Gear Assembly
DISASSEMBLY
If steering gear is to be held in a vise, avoid clamping at power cylinder portion.
1. Remove dust cover from stub shaft, Fig. 2. 2. Clean outward faces of stub shaft, then remove
retaining ring and back-up ring. 3. Remove stub shaft seal by plugging inlet hose fitting and
applying air pressure to outlet fitting. 4. Hold cover stationary and turn adjuster clockwise to
remove. 5. Clean outward faces of sector shaft, then set stub shaft in straight ahead position and
remove sector shaft. Hold sector shaft in straight ahead
position when removing shaft from gearbox.
6. Remove bolts retaining valve housing to gearbox.

7. Remove ball screw and valve housing assembly from gearbox. The ball screw and valve housing
assembly must be kept in a horizontal
position to prevent dislodging rack piston and recirculating balls.
8. Remove all piston seal rings and O-rings. 9. Clean and inspect all disassembled parts and
replace as necessary.
ASSEMBLY
1. If sector shaft bearing was removed, replace so that face with name faces outward and is flush
with recess in case, Fig. 2. 2. Install sector shaft seal ring and dust seal ring in gearbox and coat
seal lips lightly with grease. 3. Apply a thin coat of grease to rack piston O-ring and install rack
piston carefully to prevent twisting. 4. Expand seal ring and install over O-ring, then apply grease to
entire circumference of seal ring. 5. Apply a thin coat of grease to valve housing and top cover
O-rings and install carefully to prevent twisting. 6. Install ball screw and valve housing assembly
into gearbox while keeping it in a horizontal position. Handle parts carefully so O-ring fitted over
oil passage does not drop into valve housing.
7. Torque valve housing retaining bolts to 27-30 ft. lbs. 8. Install new stub shaft oil seal into valve
housing using tool J-26508. 9. Install back-up ring and retaining ring with rounded edges facing oil
seal. Install dust cover.
10. Install hose fitting with new O-ring in valve housing. 11. Torque hose fitting locknut to 30 ft. lbs.
12. Tape sector shaft spline to protect seal and install shaft so that it is centered with rack piston.
13. Thread adjusting screw into top cover and turn screw counterclockwise until top cover contacts
gearbox. Continue for two more turns, install bolts
and torque to 35 ft. lbs.
14. Check for proper installation of sector gear and rack piston by rotating stub shaft just over four
complete turns. If this cannot be accomplished
repeat step 13.
15. Measure backlash between rack piston and sector gear using an inch pound torque wrench to
measure starting torque of stub shaft. A 17mm 12
point socket may be used on the splines of the stub shaft. Starting torque should be 5.2-7.8 inch
lbs. Adjustment is made by turning adjusting screw.
16. Install new adjusting screw locknut and torque to 30 ft. lbs.
Isuzu Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and
Repair > Models With Air Bag
Steering Wheel: Service and Repair Models With Air Bag

disarming and arming procedures. 2. Remove air bag module.
Fig. 2 Steering Wheel Replacement
3. Disconnect horn lead from center of steering wheel, Fig. 2. 4. Remove steering wheel retaining
nut. 5. Using steering wheel puller tool No. J-1859-03, or equivalent, carefully remove steering
wheel from column. 6. Reverse procedure to install, noting the following:
a. Use caution to not damage harness section of coil when inserting steering wheel into column. b.
Cancel cam of combination switch must be closely inserted into boss hole in steering wheel. c.
Torque steering wheel retaining nut to 25 ft. lbs. d. Torque air bag module retaining bolts to 44 inch
lbs.
Isuzu Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and
Repair > Models With Air Bag > Page 3270
Steering Wheel: Service and Repair Models Without Air Bag
1. Disconnect battery ground cable. 2. Remove horn shroud from center of steering wheel by
removing attaching screw from behind steering wheel. 3. Remove steering wheel retaining nut. 4.
Draw an alignment mark on steering column splines for installation reference. 5. Remove steering
wheel using steering wheel puller tool No. J-29752, or equivalent. 6. Reverse procedure to install.
Torque steering wheel retaining nut to 25-29 ft. lbs.
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications
Ball Joint: Specifications
Ball Joint Starting torque, Ft. Lbs. .......................................................................................................

....................................................................... 0.9-2.4
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Page 3275
Ball Joint: Testing and Inspection
1. Remove ball joint from control arm. 2. Inspect grease boot for any cuts or any signs of leakage.
3. Swivel ball joint stem back and forth several times, ensure joint moves smoothly. 4. Install nut
onto ball joint stem, then using a suitable torque wrench, check starting torque. See: Specifications
Page 3276
Ball Joint: Service and Repair
Make necessary parts replacement if wear,
damage, corrosion or any other abnormal conditions are found through inspection. Check the
following parts: -
Upper control arm
- Bushing
- Fulcrum pin
2. Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure
to confirm its normal movement (Fig. 3C-24).
Inspect screw/taper area of ball for flaws. If any defects are found during the inspections, replace
the end assembly with new one.
3. After moving the ball joint 4 or 5 times, attach nuts, then measure the preload Fig. 3C-25).
PRELOAD TORQUE, INSPECTION AND REPAIR: Upper Link End kg.m (lb.ft.) N.m 0.1 - 0.33 (0.7
- 2.4/0.9 - 3.2)
Lower Link End kg.m (lb.ft.) N.m 0.5 - .35 (0.35 - 2.50/0.5 - 3.4)
INSTALLATION Upper Nuts final Torque N.m (ft.lb) 24 (32.4)
Lower Nuts final Torque N.m (ft.lb) 103 (76)
Nut and Cotter Pin Torque, Pick-up 4WD/Amigo N.m (lb.ft.) Upper 98 (73) Lower 94 (127.5)
Nut and Cotter Pin Torque, Pick-up 2WD N.m (lb.ft.) Upper 108 (80) Lower 147 (108.5) 1988-93
Pick-up/Amigo/Rodeo
PRELOAD TORQUE, INSPECTION AND REPAIR Upper Link End kg.m (lb.ft.) N.m 0.1 - 0.33 (0.7
- 2.4/0.9 - 3.2)
Lower Link End kg.m (lb.ft.) N.m 0.07 - 0.65 (0.51 - 4.7/0.7 - 6.4)
INSTALLATION Upper Nuts final Torque N.m (ft.lb) 24 (32.4)
Pick-up/Amigo 4WD
Page 3277
PRELOAD TORQUE, INSPECTION AND REPAIR: Upper Link End kg.m (lb.ft.) N.m 0.1 - 0.33 (0.7
- 2.4/0.9 - 3.2)
Lower Link End kg.m (lb.ft.) N.m 0.05 - 035 (0.35 - 2.50/0.5 - 3.4)
INSTALLATION Upper Nuts final Torque N.m (ft.lb) 69 (51)
Pick-up/Amigo 2WD
PRELOAD TORQUE INSPECTION AND REPAIR: Upper Link End N.m (lb.ft.) 1.3 - 3.2 (0.94 -
2.38)
Lower Link End N.m (lb.ft.) 02.5 - 6.4 (1.8 - 4.7)
Nut and Cotter Pin Torque Upper N.m (lb.ft) 98 (73)
Nut and Cotter Pin Torque Lower N.m (lb.ft) 128 (94) 1994-95 Rodeo
PRELOAD TORQUE INSPECTION AND REPAIR: Upper Link End N.m (lb.ft.) .5 - 3.2 (0.4 - 2.4)
Lower Link End N.m (lb.ft.) 0.5 - 6.4 (.4 - 4.7)
Nut and Cotter Pin Torque Lower N.m (lb.ft) 147 (108)
1996 Rodeo
PRELOAD TORQUE INSPECTION AND REPAIR: Upper Link End N.m (lb.ft.) 0.5 - 3.2 (0.4 - 2.4)
Nut and Cotter Pin Torque Lower N.m (lb.ft) 127 (94) 1988-91 Trooper II

Page 3278
Nut and Cotter Pin Torque Lower N.m (lb.ft) 127 (94) 1992-93 Trooper
Lower Link End N.m (lb.ft.) 0.5 - 6.4 (.4 - 4.7)
Nut and Cotter Pin Torque Lower N.m (lb.ft) 148 (108) 1994-96 Trooper Preload torque N.m (lb.ft.)
0.5 - 3.2 (0.4 - 2.4) If the above limits specified are exceeded, replace the end assembly.
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair
Control Arm: Service and Repair
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Remove shock absorber,
then mark position of torsion bar adjustment bolt. 3. Loosen torsion bar adjustment bolt, then
remove torsion bar. 4. Remove lower ball joint from lower control arm. 5. Remove stabilizer link
assembly from lower control arm. 6. Remove lower control arm to frame retaining bolts, then the
lower control arm from vehicle. 7. Reverse procedure to install.
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
1. Raise and support vehicle, then remove wheel and tire assembly. 2. Mark positions of torsion
bar adjusting bolt, front and rear positions of torsion bar for correct installation. 3. Loosen torsion
bar adjusting bolt, then remove hub center cover assembly. 4. Remove snap ring and shims from
hub. 5. Remove brake caliper and support with wire out of way. 6. Using removal tool No. J-29107,
or equivalent, remove tie rod end from steering knuckle. 7. Remove upper and lower cotter pins,
then ball joint retaining nuts. 8. Using removal tool No. J-29107, or equivalent, separate ball joints
from steering knuckle. 9. Remove steering knuckle from vehicle.

Isuzu Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component
Stabilizer Bar: Service and Repair
1. Raise and support front of vehicle. 2. Remove rubber bushing and washer. 3. Remove bracket.
4. Remove stabilizer bar. 5. Reverse procedure to install.
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Suspension Spring ( Coil / Leaf ): Service and Repair
Fig. 5 Exploded View Of Rear Suspension
1. Remove shock absorbers, Fig. 5. 2. Remove parking brake cable clips. 3. Remove the U-bolts.
4. Jack up the rear axle slightly to separate it from the leaf spring assemblies. 5. Remove front and
rear shackle bolt nuts and drive out rear shackle bolt. 6. Drive out the front shackle bolt and remove
the leaf spring assembly rearward. 7. Remove the shackle bolt from the rear springs bracket and
remove the shackle. 8. Reverse procedure to install. Tighten fasteners to specifications.
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension
Suspension Strut / Shock Absorber: Service and Repair Front Suspension
1. Raise and support front of vehicle.
2. Remove nut, rubber bushing and washer.
3. Remove bolt, nut and washer.
4. Remove shock absorber.

Isuzu Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Suspension > Page 3295
Suspension Strut / Shock Absorber: Service and Repair Rear Suspension
1. Raise vehicle and support with jackstands placed under frame near rear end of spring brackets.
2. Remove upper and lower shock absorber retaining nuts and remove shock absorber. 3. Reverse
procedure to install.
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and
Repair
Torsion Bar: Service and Repair
1. Raise and support front of vehicle.
Fig. 11 Torsion Bar Replacement
2. Remove adjustment bolt and seat, Fig. 11. 3. Remove height control arm. 4. Remove torsion bar
and rubber seat. 5. Reverse procedure to install.
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Adjustments > Automatic Locking Hub
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Adjustments > Automatic Locking Hub > Page 3303
washer.
Available
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Component ..........................................................................................................................................
..............................................................................................................................................................
. 76 Axle Nut ........................................................................................................................................
..................................................................................... 76 Driveshaft Nut ...........................................
..............................................................................................................................................................
........... 76 Hub Nut ..............................................................................................................................
..............................................................................................................................................................
(Front Bolt) ...........................................................................................................................................
Frame ..................................................................................................................................................
.................................................................................................................................. 61 Stabilizer Bar
.......................................................................................................................................... 8 Steering
Knuckle ................................................................................................................................................
................................................................................................................................................... 73
.............................................................................................................................................................
.................................................................................... 80 Wheel Lug Nuts .........................................
..............................................................................................................................................................
........ [01]
Isuzu Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information >
Technical Service Bulletins > Locking Hub - Special Tool
AFFECTED VEHICLES
SERVICE INFORMATION
J-29015.
Service and Repair > Automatic Locking Hub
REMOVAL
1. Bolt
Lockwasher
Service and Repair > Automatic Locking Hub > Page 3314
8. Hub nut
Wrench: J-36827
13. Bolt
14 Wheel pin
- Hub
- Knuckle spindle
- Disc
- Caliper

14. Wheel pin
completely.
13. Bolt

11. Oil seal
8. Hub nut
Wrench: J-36827
Preload adjustment
7. Lock washer
washer.
6. Inner cam
Installer: J-38194
Shim selection

washer.
of the axle shaft.

shaft.

correct.

DISASSEMBLY
knob.
ASSEMBLY

three feet.

Manual Locking Hub

Isuzu Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tires - Proper Inflation Pressure Information
Tires: Technical Service Bulletins Tires - Proper Inflation Pressure Information
Information On Proper Tire Pressure
Affected Vehicles
Service Information
IMPORTANT:
Generally a 5.6°C (10° F) temperature change will result in (is equivalent to) a 1 psi (6.9 kpa) tire
pressure change. Tires may be over inflated from the assembly plant due to the mounting process.
ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on
the vehicles placard during the PRE-DELIVERY INSPECTION.
Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure.
The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct
pressures. The recommended tire inflation pressure is listed on the vehicle's tire placard. The tire
placard is located on the driver's side front or rear door edge, or the rear compartment lid.
Tip
^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 1 psi (6.9 kpa) tire
pressure change.
^ The definition of a "cold" tire is one that has been sitting for at least 3 hours or driven no more
than 1.6 km (1 mi).
IMPORTANT:
Do not use the tire pressure indicated on the tire itself as a guide. Always inspect and adjust the
pressure when the tires are cold. Vehicles that have different pressures for the front and the rear
need to be adjusted after tire rotation.
Improper tire inflation may result in any or all of the following conditions:
^ Premature tire wear
^ Harsh ride
^ Excessive road noise
^ Poor handling
^ Reduced fuel economy
^ Low Tire Pressure Monitor (TPM) Light ON
^ Low Tire Pressure Message on the Drivers Information Center (DIC)

Isuzu Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tires - Proper Inflation Pressure Information > Page 3334
Tires: Technical Service Bulletins Radial Tire - Sidewall Indentations
GROUP TIRES & WHEELS
RADIAL TIRE SIDEWALL INDENTATIONS
AFFECTED VEHICLES
All Isuzu models equipped with radial tires.
SERVICE INFORMATION
On some affected vehicles, slight indentations may be noticeable on the sidewall surface of one or
more tires, giving the sidewall a wavy appearance.
The cause of these indentations lies in a radial tire's construction. In a radial tire, the body ply cords
run straight across the tire from bead to bead. Because of this "straight across" construction, the
joining of the ply material in the sidewall area may sometimes cause the sidewall surface to
develop slight indentations when the tire is inflated.
These sidewall indentations are a common characteristic of radial tires and will not affect the tire's
performance.
Isuzu Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Adjustments > Automatic Locking Hub
Isuzu Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Adjustments > Automatic Locking Hub > Page 3339
washer.
Available
Isuzu Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component
Component ..........................................................................................................................................
..............................................................................................................................................................
. 76 Axle Nut ........................................................................................................................................
..................................................................................... 76 Driveshaft Nut ...........................................
..............................................................................................................................................................
........... 76 Hub Nut ..............................................................................................................................
..............................................................................................................................................................
(Front Bolt) ...........................................................................................................................................
Frame ..................................................................................................................................................
.................................................................................................................................. 61 Stabilizer Bar
.......................................................................................................................................... 8 Steering
Knuckle ................................................................................................................................................
................................................................................................................................................... 73
.............................................................................................................................................................
.................................................................................... 80 Wheel Lug Nuts .........................................
..............................................................................................................................................................
........ [01]
Isuzu Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information
> Technical Service Bulletins > Locking Hub - Special Tool
AFFECTED VEHICLES
SERVICE INFORMATION
J-29015.
> Service and Repair > Automatic Locking Hub
REMOVAL
1. Bolt
Lockwasher
> Service and Repair > Automatic Locking Hub > Page 3350
8. Hub nut
Wrench: J-36827
13. Bolt
14 Wheel pin
- Hub
- Knuckle spindle
- Disc
- Caliper

14. Wheel pin
completely.
13. Bolt

11. Oil seal
8. Hub nut
Wrench: J-36827
Preload adjustment
7. Lock washer
washer.
6. Inner cam
Installer: J-38194
Shim selection

washer.
of the axle shaft.

shaft.

correct.

DISASSEMBLY
knob.
ASSEMBLY

three feet.

Manual Locking Hub

Isuzu Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Wheel Lug - Torque Stick Now Used for Installation
Wheel Fastener: Technical Service Bulletins Wheel Lug - Torque Stick Now Used for Installation
ISSUE DATE: MAY 1999
GROUP: STANDARD TOOLS
3/4" (19 mm) WHEEL LUG TORQUE STICK
AFFECTED VEHICLES
All Isuzu models (exduding Hombre) equipped with 3/4" (19 mm) wheel lug nuts.
ESSENTIAL TOOL INFORMATION
To prevent over-tightening wheel lugs on Isuzu passenger vehicles, American Isuzu Motors Inc. is
making essential a 3/4" (19 mm) wheel lug torque stick. This new tool # J-44342 must now be used
for the installation of steel/aluminum wheels on all Isuzu passenger vehicle wheels, excluding
Hombre MY96-99, I-Mark MY87-89, and P'UP MY87. The torque stick is preset to Isuzu factory
specifications and is an Isuzu essential tool.
Tool number J-44342 will be shipped free of charge to all Isuzu SUV dealerships in June 1999.
Isuzu Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > SB99-12-S001 > Jan > 99 > HVAC Blower Motor - Noisy or
Inoperative
Blower Motor: All Technical Service Bulletins HVAC Blower Motor - Noisy or Inoperative
ISSUE DATE; JANUARY 1999
GROUP: HEATING & A/C
1991-97 RODEO (UC) HVAC BLOWER MOTOR: WATER INTRUSION
AFFECTED VEHICLES 1991-97 Rodeo (UC) models.
SERVICE INFORMATION
Condition: Some affected vehicles may experience one or more of the following conditions:
^ Noisy blower motor operation
^ Loss of one or more fan speeds
^ Reduced fan speed
^ Inoperative blower motor
^ Partial or complete failure of the blower resistor
Possible Cause: Moisture may have entered the blower motor assembly if the passenger side cowl
screw is either installed incorrectly or insufficiently tightened.
Correction: Using the information outlined in this bulletin, inspect the blower system for any signs or
possibility of water intrusion. In addition, service the blower system using published procedures in
the Workshop Manual.
SERVICE PROCEDURE Follow the steps below to verify if moisture is entering the vehicle above
the blower motor assembly:
1. Remove the blower motor assembly. ^
Inspect for rust on the blower motor shaft.
2. Introduce water to the vent cowl cover area. (Figure 1)

Bulletins > All Technical Service Bulletins for Blower Motor: > SB99-12-S001 > Jan > 99 > HVAC Blower Motor - Noisy or
Inoperative > Page 3378
3. Visually inspect up through the fan case where the blower motor assembly was pre. viously
removed. (Figure 2)
4. If moisture can be seen entering the cab, the leak must be repaired. Verify that the passenger
side cowl screw is correctly tightened and apply room temperature vulcanizing (RTV) rubber
sealant to seal the leak if necessary.
NOTE
If a repair is made to the blower fan circuit and moisture continues to enter the vehicle above the
blower motor assembly, a repeat failure is possible.
Refer to the appropriate published Workshop Manual and Flat Rate Manual to service the blower
system.
Bulletins > Customer Interest for Blower Motor: > SB99-12-S001 > Jan > 99 > HVAC Blower Motor - Noisy or Inoperative
Blower Motor: Customer Interest HVAC Blower Motor - Noisy or Inoperative
ISSUE DATE; JANUARY 1999
GROUP: HEATING & A/C
1991-97 RODEO (UC) HVAC BLOWER MOTOR: WATER INTRUSION
AFFECTED VEHICLES 1991-97 Rodeo (UC) models.
SERVICE INFORMATION
Condition: Some affected vehicles may experience one or more of the following conditions:
^ Noisy blower motor operation
^ Loss of one or more fan speeds
^ Reduced fan speed
^ Inoperative blower motor
^ Partial or complete failure of the blower resistor
Possible Cause: Moisture may have entered the blower motor assembly if the passenger side cowl
screw is either installed incorrectly or insufficiently tightened.
Correction: Using the information outlined in this bulletin, inspect the blower system for any signs or
possibility of water intrusion. In addition, service the blower system using published procedures in
the Workshop Manual.
SERVICE PROCEDURE Follow the steps below to verify if moisture is entering the vehicle above
the blower motor assembly:
1. Remove the blower motor assembly. ^
Inspect for rust on the blower motor shaft.
2. Introduce water to the vent cowl cover area. (Figure 1)

Bulletins > Customer Interest for Blower Motor: > SB99-12-S001 > Jan > 99 > HVAC Blower Motor - Noisy or Inoperative >
Page 3384
3. Visually inspect up through the fan case where the blower motor assembly was pre. viously
removed. (Figure 2)
4. If moisture can be seen entering the cab, the leak must be repaired. Verify that the passenger
side cowl screw is correctly tightened and apply room temperature vulcanizing (RTV) rubber
sealant to seal the leak if necessary.
NOTE
If a repair is made to the blower fan circuit and moisture continues to enter the vehicle above the
blower motor assembly, a repeat failure is possible.
Refer to the appropriate published Workshop Manual and Flat Rate Manual to service the blower
system.
Isuzu Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Blower Motor: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Blower Motor: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Blower Motor: Electrical Diagrams
Heater
Isuzu Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page
3409
Blower Motor: Testing and Inspection
BLOWER MOTOR
1. Disconnect the 2P (B-4) connector from the blower motor. 2. Connect the battery positive
terminal to the No. 1 terminal of the blower motor and negative to the No. 2. 3. Be sure to check to
see if the blower motor operates correctly.
Isuzu Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page
3410
Blower Motor: Service and Repair
1. Remove floor distribution ducts and glove compartment, as necessary to gain access to motor.
2. Disconnect electrical connector from blower motor. 3. Remove screws securing motor mounting
plate to housing. 4. Remove motor assembly. Take care not to damage seal. 5. Remove retaining
ring securing impeller, then the impeller. 6. Reverse procedure to install.
Isuzu Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and
Inspection
Blower Motor Resistor: Testing and Inspection
RESISTOR
1. Disconnect the 6P (B-I) connector. 2. Check for continuity and resistance between the terminals
of the resistor.
Isuzu Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams >
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Isuzu Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview
Inspection > Initial Inspection and Diagnostic Overview > Page 3441

Inspection > Initial Inspection and Diagnostic Overview > Page 3442
Isuzu Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Compressor Clutch: Specifications
Clearance 0.3-0.6 mm
Compressor Clutch: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Compressor Clutch: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Compressor Clutch: Electrical Diagrams
Air Conditioner: Compressor Control 3.2L

Air Conditioner: Compressor Control 3.2L (Automatic Only)
Compressor Clutch: Testing and Inspection

MAGNETIC CLUTCH DIAGNOSIS
When the air conditioning switch and the fan control knob (fan switch) are turned on with the
engine running, current flows through the thermo switch (and the compressor) relay(s) to activate
the magnetic clutch.
The air conditioning can be stopped by turning off the air conditioning switch or the fan control lever
(fan switch). However, even when the air conditioning is in operation, the electronic thermostat, the
pressure switch or the Engine Control Module (ECM: V6 Engine) is used to stop the air
conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to reduce
the engine load which is being caused by the rise in the engine coolant temperature, and the
acceleration of the vehicle, etc.
For the inspection of the relays, switches and units in the flow chart, refer to individual components
testing and inspection."
Compressor Clutch: Service and Repair
MAGNETIC CLUTCH ASSEMBLY
REMOVAL
1. Drive plate bolt
- Using drive plate holder (J-33939) to prevent the drive plate from rotating, then remove the bolt.
2. Drive plate
- Using drive plate puller (J-33944-A) and forcing screw (J-33944-4) to remove the drive plate.
3. Shim(s)
- Always count the number of shim(s), to insure the proper number of shim(s) during installation.
4. Snap ring
5. Cover
- Using snap ring pliers to remove the snap ring.
6. Pulley assembly
- Using pulley puller pilot (J-33943-A) and pulley puller (J-8433) to remove the pulley assembly.
7. Lead wire
- Remove the lead wire from lead wire fixing bush.

8. Field coil
- Loosen three screws and remove the field coil with lead wire.
INSTALLATION
8. Field coil
7. Lead wire
- Install the field coil to the compressor.
- Lead wire must be facing up.
- Tighten the field coil fixing screws to the specified torque.
Torque N-m (lb.in.) 5.0 (44)
6. Magnetic clutch pulley
- Using pulley installer (J-33940-A) and drive handle (J-8092) to install the magnetic clutch pulley.
5. Cover
4. Snap ring
- Install the snap ring with the inside indented portion facing out.
3. Shim(s)
2. Drive plate
- Install the magnetic clutch armature to the compressor drive shaft together with the original
shim(s).
- Press the magnetic clutch armature by hand.
1. Drive plate bolt
- Using drive plate holder (J-33939) to prevent the drive plate from rotating.
- Tighten the bolt to the specified torque.
Torque N.m (lb.ft.) 15(11)
- After tightening the bolt, check to be sure the pulley rotates smoothly.
- Check to be sure that the clutch clearance is between 0.3-0.6 mm (0.01-0.02 in.).
- If necessary, install adjusting shim(s).
- Adjusting shims are available in the following thickness.

Isuzu Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Picture 19
Fuse Panel
Isuzu Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component
Condenser Fan Motor: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Condenser Fan Motor: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Condenser Fan Motor: Initial Inspection and Diagnostic Overview
CONDENSER FAN
1. Disconnect the condenser fan connector. 2. Connect the battery positive terminal to the
condenser fan side connector terminal NO. A-54-1 and negative to the No. A-54-2. 3. Check that
condenser fan is rotating correctly.
Condenser Fan Motor: Symptom Related Diagnostic Procedures
Condenser Fan Does Not Run

Condenser Fan Does Not Run (Cont.)
Condenser Fan Does Not Stop

Isuzu Workshop Manuals > Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information >
Locations
Picture 15
Fuse Panel
Isuzu Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > SB99-12-S002 > Mar > 99 > HVAC System - Unpleasant
Odors When In Use
Evaporator Case: All Technical Service Bulletins HVAC System - Unpleasant Odors When In Use
ISSUE DATE: MARCH 1999
GROUP: AIR CONDITIONING
AFFECTED VEHICLES
All Isuzu light vehicles equipped with air conditioning.
SERVICE INFORMATION
Condition: Some Isuzu owners may experience unpleasant odors when using the ventilation
system. These odors may be more pronounced after engaging the HVAC system, especially within
12 to 24 hours after previous use.
Possible Cause: The above condition is typically caused by residual c6ndensation in the
evaporator case after A/C use. The odor can be aggravated by particulates such as: cigarette/cigar
smoke, airborne molds, pollen, algae and bacteria trapped in the HVAC system and continually
recirculated.
Correction: To minimize or eliminate unpleasant odors originating from the HVAC system, use
available tool # J43681-A (Figure 1) to perform the procedure outlined in this bulletin.
SERVICE PROCEDURE
1. Set the temperature selector to the warmest setting and select A/C off.
2. Dry the A/C evaporator by running hot air over the core with the mode control knob on
recirculation mode for approximately five (5) minutes.
* On some models (without the manual A/C ON/OFF button), select "MAX A/C" mode with A/C fuse
removed to disable the A/C compressor.
3. Remove the glove box while drying the A/C evaporator.

Odors When In Use > Page 3524
4. Drill 5/16"(8 mm) hole in the upper-right corner of the evaporator case. (Figure 2)
CAUTION
Be certain to set the drill bit depth at no more than 1/4" (6 mm). Mark the drill bit 1/4"(6 mm) or less
from its tip as a guide. Extending the drill bit deeper into the case after the hole has been drilled will
risk puncturing the evaporator core.
5. With the blower fan on medium to high speed and using the outside air setting, dispense the
deodorizer material J43681-A (w/applicator nozzle) with the following:
^ Place the tip of the nozzle into the 5/16"(8 mm) drilled hole of A/C evaporator core casing. (Figure
3)
^ Using no more than 30 PSI shop air, set nozzle fluid flow adjustment to full open position (full
counterclockwise position), and flood the A/C evaporator core by discharging 4 fluid ounces of
treatment chemical into the casing.
NOTE
2 fluid ounces are required to prime the application tubing and nozzle. The 1/2 gallon container
label is graduated in 4 ounce increments.
6. Plug the 5/16" (8 mm) hole with a 5/16" (8 mm) plug supplied with each treatment kit.
7. Run the ventilation system 5-10 minutes with the fan on high and windows open.
8. Reinstall the glove box and any panels, previously removed during Step 2.
* Reinstall the A/C fuse, if previously removed.

The application should last 3-4 months under normal use. Repeat the above service procedure,
should odors return after such time.
NOTE
As a preventive measure, service personnel may also suggest to the customer to run the fan
blower at mid to high speed with the A/C off and using the outside air setting to dry the evaporator
for the last few minutes before turning off the vehicle.
PARTS INFORMATION
KENT-MOORE Part Number Description Quantity
J43681-A HVAC SYSTEM 1 Kit*
Cleaner-Freshner-Protectant with application nozzle
J43681-5 Replacement Chemical (Refill)
(2-1/2 gallon containers)
* A sufficient quantity of 5/16"(6 mm) plug is included with each treatment kit.
NOTE:This product will be available for purchase beginning mid-April 1999.
GREEN ISLAND INC. WARRANTY INFORMATION

Odors When In Use > Page 3525
Please refer to the warranty information included with each HVAC system treatment kit. Green
Island Inc. warrants to the buyers that the products are free from defects with a 1 year Limited
Warranty. For inquiries regarding warranty claim information for Green Island Inc. products contact
their customer support at 1-800.718-1131.
ISUZU WARRANTY CLAIM INFORMATION
Isuzu warranty does not cover this service.

Bulletins > All Technical Service Bulletins for Evaporator Case: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist
From Vents
Evaporator Case: All Technical Service Bulletins A/C System - Poor Cooling/Mist From Vents
AFFECTED VEHICLES
SERVICE INFORMATION
minutes.
SERVICE PROCEDURE
NOTE
follows:
NOTE:
From Vents > Page 3530

PARTS INFORMATION
NOTE:

Bulletins > Customer Interest for Evaporator Case: > SB99-12-S002 > Mar > 99 > HVAC System - Unpleasant Odors When
In Use
Evaporator Case: Customer Interest HVAC System - Unpleasant Odors When In Use
ISSUE DATE: MARCH 1999
AFFECTED VEHICLES
All Isuzu light vehicles equipped with air conditioning.
SERVICE INFORMATION
Condition: Some Isuzu owners may experience unpleasant odors when using the ventilation
system. These odors may be more pronounced after engaging the HVAC system, especially within
12 to 24 hours after previous use.
Possible Cause: The above condition is typically caused by residual c6ndensation in the
evaporator case after A/C use. The odor can be aggravated by particulates such as: cigarette/cigar
smoke, airborne molds, pollen, algae and bacteria trapped in the HVAC system and continually
recirculated.
Correction: To minimize or eliminate unpleasant odors originating from the HVAC system, use
available tool # J43681-A (Figure 1) to perform the procedure outlined in this bulletin.
SERVICE PROCEDURE
1. Set the temperature selector to the warmest setting and select A/C off.
2. Dry the A/C evaporator by running hot air over the core with the mode control knob on
recirculation mode for approximately five (5) minutes.
* On some models (without the manual A/C ON/OFF button), select "MAX A/C" mode with A/C fuse
removed to disable the A/C compressor.
3. Remove the glove box while drying the A/C evaporator.

In Use > Page 3537
4. Drill 5/16"(8 mm) hole in the upper-right corner of the evaporator case. (Figure 2)
CAUTION
Be certain to set the drill bit depth at no more than 1/4" (6 mm). Mark the drill bit 1/4"(6 mm) or less
from its tip as a guide. Extending the drill bit deeper into the case after the hole has been drilled will
risk puncturing the evaporator core.
5. With the blower fan on medium to high speed and using the outside air setting, dispense the
deodorizer material J43681-A (w/applicator nozzle) with the following:
^ Place the tip of the nozzle into the 5/16"(8 mm) drilled hole of A/C evaporator core casing. (Figure
3)
^ Using no more than 30 PSI shop air, set nozzle fluid flow adjustment to full open position (full
counterclockwise position), and flood the A/C evaporator core by discharging 4 fluid ounces of
treatment chemical into the casing.
NOTE
2 fluid ounces are required to prime the application tubing and nozzle. The 1/2 gallon container
label is graduated in 4 ounce increments.
6. Plug the 5/16" (8 mm) hole with a 5/16" (8 mm) plug supplied with each treatment kit.
7. Run the ventilation system 5-10 minutes with the fan on high and windows open.
8. Reinstall the glove box and any panels, previously removed during Step 2.
* Reinstall the A/C fuse, if previously removed.

The application should last 3-4 months under normal use. Repeat the above service procedure,
should odors return after such time.
NOTE
As a preventive measure, service personnel may also suggest to the customer to run the fan
blower at mid to high speed with the A/C off and using the outside air setting to dry the evaporator
for the last few minutes before turning off the vehicle.
PARTS INFORMATION
KENT-MOORE Part Number Description Quantity
J43681-A HVAC SYSTEM 1 Kit*
Cleaner-Freshner-Protectant with application nozzle
J43681-5 Replacement Chemical (Refill)
(2-1/2 gallon containers)
* A sufficient quantity of 5/16"(6 mm) plug is included with each treatment kit.
NOTE:This product will be available for purchase beginning mid-April 1999.
GREEN ISLAND INC. WARRANTY INFORMATION

In Use > Page 3538
Please refer to the warranty information included with each HVAC system treatment kit. Green
Island Inc. warrants to the buyers that the products are free from defects with a 1 year Limited
Warranty. For inquiries regarding warranty claim information for Green Island Inc. products contact
their customer support at 1-800.718-1131.
ISUZU WARRANTY CLAIM INFORMATION
Isuzu warranty does not cover this service.

Bulletins > Customer Interest for Evaporator Case: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents
Evaporator Case: Customer Interest A/C System - Poor Cooling/Mist From Vents
AFFECTED VEHICLES
SERVICE INFORMATION
minutes.
SERVICE PROCEDURE
NOTE
follows:
NOTE:
Bulletins > Customer Interest for Evaporator Case: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents >
Page 3543

Bulletins > Customer Interest for Evaporator Case: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents >
Page 3544
PARTS INFORMATION
NOTE:

Evaporator Case: Service and Repair
EVAPORATOR ASSEMBLY
Evaporator Assembly
REMOVAL
Preparation:
- Disconnect battery ground cable.
- Discharge and recover refrigerant.
1. Glove box 2. Center console 3. Speaker cover 4. Air duct 5. Resister and electronic thermostat
connector 6. Drain hose 7. Refrigerant line
- Use a back-up wrench when disconnecting and reconnecting the refrigerant lines.
- When removing the refrigerant line connected part, the connecting part should immediately be
plugged or capped to prevent foreign matter from being mixed into the line.
8. Evaporator assembly
Take care to avoid damaging the antenna cable.
INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points.
1. To install the drain hose, insert with the white marking facing up. 2. To install a new evaporator
assembly, add 50 cc (1.7 fl.oz) of new compressor oil to a new core. 3. Tighten the refrigerant
outlet line to the specified torque.
4. Tighten the refrigerant inlet line to the specified torque.
Torque N.m (lb.in) 15 (11)
5. O-rings cannot be reused. Always replace with new ones. 6. Be sure to apply new compressor
oil to the O-rings when connecting lines.
Isuzu Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
Evaporator Core: Service and Repair
EVAPORATOR CORE AND/OR EXPANSION VALVE
REMOVAL
Preparation:
-Battery ground cable -Discharge and recover refrigerant
1. Evaporator assembly (Refer to Evaporator Case ) 2. Clip 3. Attaching screw 4. Uppercase 5.

Lower case
Isuzu Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
> Page 3549
- Slit the case parting face with a knife since the lining is separated when removing the evaporator.
- Lift to remove the upper case.
6. Evaporator core 7. Expansion valve
- Tear off the insulator carefully.
- Remove the sensor fixing clip.
- Use a back-up wrench when disconnecting all refrigerant pipes.
INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points:
oil to the O-rings when connecting lines. 3. Be sure to install the sensor and the insulator in their
previous positions. 4. To install a new evaporator core, add 50 cc (1.7 ft.oz.) of new compressor oil
to a new core. 5. Tighten the refrigerant lines to the specified torque. 6. Apply an adhesive to
parting face of lining when assembly evaporator assembly.
Isuzu Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: >
SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction
Correction
1993 A/C THERMOSTAT
AFFECTED VEHICLES
conditioning.
SERVICE INFORMATION
thermostat:
SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction > Page 3558
affected vehicles.
9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents
AFFECTED VEHICLES
SERVICE INFORMATION
minutes.
SERVICE PROCEDURE
NOTE
follows:
NOTE:
9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents > Page 3564

9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents > Page 3565
PARTS INFORMATION
NOTE:

Information > Technical Service Bulletins > Customer Interest: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist
From Vents
Vents
AFFECTED VEHICLES
SERVICE INFORMATION
minutes.
SERVICE PROCEDURE
NOTE
follows:
NOTE:

PARTS INFORMATION
NOTE:

Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Temperature Sensor / Switch: >
SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction
Correction
1993 A/C THERMOSTAT
AFFECTED VEHICLES
conditioning.
SERVICE INFORMATION
thermostat:
affected vehicles.
Picture 15
Isuzu Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair
Expansion Valve: Service and Repair
EVAPORATOR CORE AND/OR EXPANSION VALVE
REMOVAL
Preparation:
-Battery ground cable -Discharge and recover refrigerant
1. Evaporator assembly (Refer to Evaporator Case ) 2. Clip 3. Attaching screw 4. Uppercase 5.

Lower case
Isuzu Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Page 3584
- Slit the case parting face with a knife since the lining is separated when removing the evaporator.
- Lift to remove the upper case.
6. Evaporator core 7. Expansion valve
- Tear off the insulator carefully.
- Remove the sensor fixing clip.
- Use a back-up wrench when disconnecting all refrigerant pipes.
INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points:
oil to the O-rings when connecting lines. 3. Be sure to install the sensor and the insulator in their
previous positions. 4. To install a new evaporator core, add 50 cc (1.7 ft.oz.) of new compressor oil
to a new core. 5. Tighten the refrigerant lines to the specified torque. 6. Apply an adhesive to
parting face of lining when assembly evaporator assembly.
Isuzu Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant Leakage
Heater Core: All Technical Service Bulletins Heater Core - Coolant Leakage
NOTE:
AFFECTED VEHICLES

SERVICE PROCEDURE
PARTS INFORMATION
Bulletins > All Technical Service Bulletins for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant Leakage >
Page 3593

Bulletins > Customer Interest for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant Leakage
Heater Core: Customer Interest Heater Core - Coolant Leakage
NOTE:
AFFECTED VEHICLES

SERVICE PROCEDURE
PARTS INFORMATION
Bulletins > Customer Interest for Heater Core: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant Leakage > Page 3599

Heater Core: Service and Repair
to 20-22 ft. lbs.
Isuzu Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Heater Core Case: > SB00-12-S003 > Jun > 00 > Heater Core -
Coolant Leakage
Heater Core Case: All Technical Service Bulletins Heater Core - Coolant Leakage
NOTE:
AFFECTED VEHICLES
SERVICE PROCEDURE
PARTS INFORMATION
Service Bulletins > All Technical Service Bulletins for Heater Core Case: > SB00-12-S003 > Jun > 00 > Heater Core -
Coolant Leakage > Page 3609

Service Bulletins > Customer Interest for Heater Core Case: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant Leakage
Heater Core Case: Customer Interest Heater Core - Coolant Leakage
NOTE:
AFFECTED VEHICLES

SERVICE PROCEDURE
PARTS INFORMATION
Service Bulletins > Customer Interest for Heater Core Case: > SB00-12-S003 > Jun > 00 > Heater Core - Coolant Leakage
> Page 3615

Heater Core Case: Service and Repair
to 20-22 ft. lbs.
Isuzu Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service
Bulletins > A/C - Receiver Dryer Replacement Recommendations
Receiver Dryer: Technical Service Bulletins A/C - Receiver Dryer Replacement Recommendations
REPLACEMENT OF THE RECEIVER DRIER DURING AIR CONDITIONING AND SERVICE
AFFECTED VEHICLES All Isuzu vehicles
SERVICE INFORMATION
In the past, it has been common repair procedure to replace the receiver drier whenever the
system is opened. Further testing has confirmed that replacement of the receiver drier is not
necessary unless the receiver drier has been left open exposed to the atmosphere for several
hours or found to be defective. A defective receiver drier is one that is:
^ Leaking
^ Restricted
IMPORTANT:
If proper diagnosis concludes that the receiver drier is leaking or is restricted, then the receiver
drier should be replaced.
In addition, there are two other conditions when a receiver drier should be replaced even though it
is not the cause of the failure. The Receiver Drier should be replaced when either or both of the
following two conditions exists:
^ when the refrigerant oil contains metallic particles
^ When the Air Conditioning Compressor is seized.
Special Service Note:
In order to maximize the life of the A/C System and maintain maximum performance, the following
precautions should be performed:
^ Anytime an Air Conditioning component is disconnected for servicing, the opening should be
capped until the repair is to be completed.
^ If a new Receiver Drier is installed during a repair, it should be the last component installed.
^ The system should be properly evacuated and recharged. The evacuation should achieve a
maximum vacuum for at least 30 minutes to boil out all the moisture out of the system.
It is imperative to remember that the receiver drier has three distinct tasks, they are:
^ To provide a reservoir to enable a consistent flow of liquid refrigerant and refrigerant oil to the rest
of the Air Conditioning system when correctly charged.
^ To provide filtration and straining of unwanted particles within the system.
^ To remove unwanted moisture from the system using desiccant material contained in the
Receiver Drier.
NOTE:
By performing the service tips as indicated, the Air Conditioning system should perform according
to the manufacturer's specifications.
Disclaimer
Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - SAE J2788 Refrigerant Recovery Standard
Refrigerant: Technical Service Bulletins A/C - SAE J2788 Refrigerant Recovery Standard
Information: IB07-12-S004
Issue Date: AUGUST 2007
Affected Vehicles All Isuzu Light Duty Vehicles
Service Information
A new SAE standard approved for R134a Refrigerant Recovery Recharging Equipment (SAE
J2788) replaces SAE J2210 as the standard covering all mobile refrigerant recovery recharge
equipment. SAE J2788 contains several mandates that enhance vehicle A/C service for two key
reasons. The standard reduces the amount of refrigerant that can be lost to the atmosphere due to
growing concerns over global warming and greenhouse gas emissions. The standard also more
tightly controls the equipment accuracy for recharging due to OEM vehicle system refrigerant
capacities becoming smaller, which requires a more accurate charge for peak operating
performance. SAE J2788 will supersede J2210 in December 2007. At this time manufacturers will
no longer be able to produce J2210 equipment.
IMPORTANT:
This new standard does not affect equipment already produced before December 2007. You DO
NOT have to replace the equipment that you are currently using.
The Environmental Protection Agency (EPA) is currently in the process of rewriting the Federal
Registry, which will likely prohibit sale of SAE J2210 equipment at the end of March 2008.
^ The EPA does not currently have a plan to ban the use of J2210 equipment.
^ Current J2210 equipment can continue to be used by service locations for the useful life of the
equipment.
^ Purchase of new compliant equipment is not a requirement of SAE J2788 or the EPA.
New machinery built after December 2007 will meet or exceed the new specifications.
The SPX Robinair model 34788 was the first product certified to J2788 and has been in full
production and in service since December 2006. It meets all requirements outlined above and
includes numerous user friendly features beyond the SAE standard.
Please contact Isuzu Dealer Equipment Program Customer Service for additional product
information.
Disclaimer
Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - SAE J2788 Refrigerant Recovery Standard > Page 3625
Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Precautions
Contaminated R134A Refrigerant Found On Market For Automotive Air-Conditioning Systems
Affected Vehicles
All Isuzu Vehicles using R134a Refrigerant
Service Information
Commercially Available Contaminated R134a Refrigerant
Impurities have been found in new commercially available containers of R134a. High levels of
contaminates may cause decreased performance, and be detrimental to some air-conditioning
components. Accompanying these contaminates has been high levels of moisture.
NOTE:
Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced
performance.
Industry Reaction: New Industry Purity Standards
Due to the potential availability of these lower quality refrigerants, the Society of Automotive
Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of
instituting reliable standards that will be carried on the labels of future R134a refrigerant containers.
This identifying symbol will be your assurance of a product that conforms to the minimum standard
for OEM Automotive Air-Conditioning use.
How Can You Protect Yourself Today?
It is recommended to use Isuzu sourced refrigerants for all A/C repair work. These refrigerants
meet Isuzu Motors America, Inc.'s own internal standards for quality and purity.
Parts Information
Disclaimer
Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Refrigerant: Capacity Specifications
Refrigerant Type R-12
System Capacity 1.65 lb (US)

Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Refrigerant: Fluid Type Specifications
Refrigerant Type ..................................................................................................................................

.......................................................................... R-12
Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
3629
Refrigerant: Service Precautions
Service Procedures
The Ozone Layer
A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a protective cover by
absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun.
Ozone Depletion
Scientific research performed over the past 15 years links the release of chlorofluorocarbons
(CFC)s, also know by the trade name Freon) into the atmosphere to ozone depletion. When CFC's
are released into the atmosphere, they eventually reach the ozone layer located in the stratosphere
where they react with and destroy ozone molecules.
Harmful Effects
Ozone depletion and the corresponding increase in UV radiation has been shown to lead to higher
incidents of cancer as well as global warming. When viewed from a global perspective, ozone
depletion holds an enormous potential for damage.
Upper Level vs. Ground Level Ozone
Confusion often arises when we hear about the necessity of the ozone layer and ground level
ozone. The ozone layer existing high above the earth is beneficial but the same compound, when
located at ground level, is harmful to humans, animals, crops and vegetation.
Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with
nitrogen oxides (NOx) in the presence of sunlight and heat.
Montreal Protocol
In response to the growing body of evidence demonstrating the detrimental effects of (CFC)s, 24
countries and the European community met in Montreal, Canada, in 1987 to establish standards for
the control of (CFC)s. Since that time, a total of 132 countries have become signatories to this
agreement leading to an end of production of R12 in December, 1995, in all developed countries.
As established by the Montreal Protocol, R12 production in developed countries has ceased.
Clean Air Act
The United States Congress, acting in response to the Montreal Protocol, banned production of
(CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to control both the
production and use of (CFC)s for refrigerant applications including mobile vehicle air conditioning
systems.
Alternative Refrigerants
The introduction of alternative refrigerants, primarily the hydrofluorocarbon (HFC) 134a, aims at
preventing further ozone layer depletion. Because 134a is chlorine free, it is deemed ozone safe.
Technician Certification
Organizations providing technician refrigerant recovery and recycling certification include:
National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2
Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/
International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX
76147-2000 Phone: (817) 338-1100 Fax: (817) 338-1451
Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041
Phone: 215-679-2220 Fax: 215-541-4635 http://www.macsw.org/
Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Refrigerant Oil: Capacity Specifications
Oil Type/Viscosity DKV-14D Compressor D-220WX
or equivalent.
DKS-17CH Compressor FREOL DS-83P
or equivalent.
Total System Capacity 5.0 oz (US)

Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Refrigerant Oil: Fluid Type Specifications
Oil Type/Viscosity R-4 Compressor 525
DKS-13 Compressor FREOL DS-83P
or equivalent.
Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Testing and Inspection > Dual Pressure Switch

Isuzu Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Testing and Inspection > Dual Pressure Switch > Page 3639
operates.
Isuzu Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Picture 19
Fuse Panel
Isuzu Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay,
HVAC > Component Information > Locations
Picture 15
Fuse Panel
Isuzu Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > System Relay, HVAC >
Picture 15
Fuse Panel
Component Information > Testing and Inspection > Heater Relay
HEATER RELAY

Component Information > Testing and Inspection > Heater Relay > Page 3652
Isuzu Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3681

Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3682
Isuzu Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest: > 9312003 > Jul > 93 > A/C
System - Poor Cooling/Mist From Vents
Vents
AFFECTED VEHICLES
SERVICE INFORMATION
minutes.
SERVICE PROCEDURE
NOTE
follows:
NOTE:
System - Poor Cooling/Mist From Vents > Page 3691

System - Poor Cooling/Mist From Vents > Page 3692
PARTS INFORMATION
NOTE:

Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator
Temperature Sensor / Switch: > SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction
Correction
1993 A/C THERMOSTAT
AFFECTED VEHICLES
conditioning.
SERVICE INFORMATION
thermostat:
Temperature Sensor / Switch: > SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction > Page 3698
affected vehicles.
Temperature Sensor / Switch: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents
AFFECTED VEHICLES
SERVICE INFORMATION
minutes.
SERVICE PROCEDURE
NOTE
follows:
NOTE:
Temperature Sensor / Switch: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents > Page 3704

Temperature Sensor / Switch: > 9312003 > Jul > 93 > A/C System - Poor Cooling/Mist From Vents > Page 3705
PARTS INFORMATION
NOTE:

Sensor / Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator
Temperature Sensor / Switch: > SB9312005 > Dec > 93 > A/C Thermostat - Manual Correction
Correction
1993 A/C THERMOSTAT
AFFECTED VEHICLES
conditioning.
SERVICE INFORMATION
thermostat:
affected vehicles.
Sensor / Switch > Component Information > Technical Service Bulletins > Page 3713
Picture 15
Isuzu Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Testing and Inspection > Dual Pressure Switch

Isuzu Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Testing and Inspection > Dual Pressure Switch > Page 3718
operates.
Isuzu Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Locations
Picture 15
Fuse Panel
Isuzu Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Testing and
Inspection > Heater Relay
HEATER RELAY

Isuzu Workshop Manuals > Heating and Air Conditioning > System Relay, HVAC > Component Information > Testing and
Inspection > Heater Relay > Page 3724
Isuzu Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping
Undeployed Air Bag
> Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 3731

LAW.
Deployed Air Bag
total particulate.
result.
diagnose.
> Service Precautions > Page 3736
PRECAUTIONS
signs of damage.
Isuzu Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service
Precautions > Air Bag Assembly Handling/Shipping/Scrapping
Air Bag: Service Precautions Air Bag Assembly Handling/Shipping/Scrapping
Undeployed Air Bag
personal injury, or unnecessary SRS repairs. See: Air Bag(s) Arming and Disarming
"SRS Diagnostic System Check" will verify proper "
AIR BAG" warning lamp operation and will lead you to the correct chart to diagnose any SRS
Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 3741

LAW.
Deployed Air Bag
total particulate.
Air Bag: Service Precautions Electrical Test Equipment
Air Bag: Service Precautions Wiring
diagnose.
Precautions > Page 3745
Air Bag: Testing and Inspection
Isuzu Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Assembly
Air Bag: Service and Repair Driver Air Bag Assembly
Airbag Deployment and Disposal (Inside Vehicle)
Deployment inside vehicle is proper when the vehicle is to be destroyed or salvaged for component
parts. This includes, but is not limited to, the
following situations.
1. he vehicle has completed its useful life. 2. The vehicle has been damaged beyond repair in a
non-deployment type accident. 3. The vehicle has been stripped or damaged beyond repair in a
theft. 4. The vehicle will be salvaged for component parts to be used on a vehicle with a different
Vehicle Identification Number (VIN) as opposed to
being rebuilt as same VIN. Never use SRS components from another vehicle.

INJURY. UNDEPLOYED AIR BAG ASSEMBLIES MUST NOT BE DISPOSED OF THROUGH
NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT
WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE AND/OR LOCAL
LAWS.
1. Turn ignition switch to "LOCK", remove key and put on safety glasses. 2. Remove all loose
objects from front seats. 3. Disconnect SRS coil assembly, yellow 3-way connector located at the
base of the steering column. 4. Cut the SRS coil assembly yellow 3-way harness connector from
the vehicle leaving at least 16cm (six inches) of wire at the connector. 5. Strip 13 mm (1/2 inch) of
insulation from yellow - green and yellow - black wire lead of the connector. 6. Cut two 900 cm (30
feet) deployment wires from 0.Bmm2 (18 gauge) or thicker multi-strand wire. These wires will be
used to fabricate the driver
deployment harness.
7. Strip 13 mm (1/2 inch) of insulation from both ends of the wires cut in the previous step. 8. Short
the wires by twisting together one end from each. Deployment wires shall remain shorted and not
be connected to a power source until the
air bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN

PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS.
DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT.
WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
9. Twist together one connector wire lead to one deployment wire. The connection should be
mechanically secure.
10. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to
insulate and secure. 11. Twist together, bend and tape the remaining connector wire lead to the
remaining deployment wire. 12. Connect the deployment harness to the driver air bag assembly,
yellow 3-way connector at the base of the steering column. Route deployment
harness out the driver side of the vehicle.

WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO
A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY
WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO
IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS
BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY.
13. Disconnect passenger air bag assembly, yellow 2-way connector located behind glove box
assembly. 14. Cut the passenger air bag assembly harness connector from the vehicle leaving at
least 16cm (six inches) of wire at the connector. 15. Strip 13 mm (1/2 inch) of insulation from
orange-blue and pink-blue wire lead of the connector. 16. Cut two 900 cm (30 feet) deployment
wires from 0.8mm2 (18 gauge) or thicker multi- strand wire. These wires will be used to fabricate
the
passenger deployment harness.
17. Strip 13 mm (1 /2inch) of insulation from both ends of the wires cut in the previous step. 18.
Short the wires by twisting together one end from each. Deployment wires shall remain shorted and
not be connected to a power source until the
air bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN

PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS.
DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIRBAG WHEN SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
> Driver Air Bag Assembly > Page 3748
19. Twist together one connector wire lead to one deployment wire. The connection should be
mechanically secure. 20. Bend twisted connection made in the previous step flat and wrap tightly
with electrical tape to insulate and secure. 21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment wire. 22. Connect the deployment harness to the
passenger air bag assembly, yellow 2-way connector located behind the glove box assembly.
Route
deployment harness out the passenger side of the vehicle.

A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY
IT. CONNECTING THE DEPLOYMENT WIRES SHOULD ALWAYS BE THE FINAL STEP IN THE
AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED COULD RESULT IN PERSONAL INJURY.
23. Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people
and loose or flammable objects. 24. Stretch the driver and passenger deployment harness to their
full length. 25. Completely cover windshield area and front door window openings with a drop cloth,
blanket or similar item. This reduces the possibility of injury
due to possible fragmentation of the vehicle's glass or interior.
26. Notify all people in the immediate area that you intend to deploy the air bags. The deployment
will be accompanied by a substantial noise which
may startle the uninformed.
27. Separate the two ends of the driver deployment harness wires.

A POWER SOURCE UNTIL THE AIR BAG IS TO A POWER SOURCE UNTIL THE AIR BAG IS
TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG
WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES
TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG
ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL INJURY.
NOTE: When the air bag deploys, the rapid gas expansion will create a substantial report. Notify all
people in the immediate area that you intend to deploy the air bags.
28. Connect the driver deployment harness wires to a power source to immediately deploy the
driver air bag assembly. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle battery is suggested.
29. Separate the two ends of the passenger deployment harness wires.

A POWER SOURCE UNTIL THE AIR BAG IS TO A POWER SOURCE UNTIL THE AIR BAG IS
TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG
WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES
TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG
ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL INJURY.
30. Connect the passenger deployment harness wires to a power source to immediately deploy the
passenger air bag assembly. Recommended
application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. Put on a pair of
shop gloves and safety gasses to protect your hands and eyes from possible irritation and heat
when handling the deployed air bag assembly. After an air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch
(used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium
hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The
sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium
carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide
will be present after deployment.
WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED

AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG
ASSEMBLY WILL BE VERY HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE
HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE HOT DEPLOYED AIR BAG
ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES
COULD RESULT IN FIRE OR PERSONAL INJURY.
After an air bag assembly has been deployed, the metal canister and surrounding areas of the air
bag assembly will be very hot. Do not touch the metal areas of the air bag assembly for about 30
minutes after deployment. If the deployed air bag assembly must be moved before it is cool, wear
gloves and handle by the air bag or trim cover.
31. Short the driver deployment harness wires by twisting together one end from each. Repeat this
procedure for the passenger deployment harness.
32. Carefully remove drop cloth from vehicle and clean off any fragments or discard drop cloth
entirely. 33. Disconnect driver deployment harness and passenger deployment harness from
vehicle and discard. 34. In the unlikely event that either or both of the air bag assemblies did not
deploy after following these procedures, proceed immediately with Steps
36 through 37. If the air bag assembly deployed, proceed to step 35.
35. With both air bags deployed, the vehicle may be scrapped in the same manner as a non-SRS
equipped vehicle.
NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did
not deploy after following these procedures.
36. Remove the undeployed air bag assembly (s) from the vehicle.
WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR
BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A
FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT
OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN
PERSONAL INJURY.
37. Temporarily store the air bag assembly with the air bag opening facing up, away from the
surface upon which it rests.
DEPLOYED AIR BAG ASSEMBLY HANDLING
Airbag Deployment and Disposal (Outside Vehicle)
DEPLOYMENT OUTSIDE VEHICLE (DRIVER AIR BAG ASSEMBLY) -
Deployment outside the vehicle is proper when the vehicle is to be returned to service. This
includes, for example, situations in which the vehicle will be returned to useful service after a
functionally or cosmetically deficient air bag assembly is replaced. Deployment and disposal of a
malfunctioning air bag assembly is, of course, subject to any required retention period.
- For deployment of a live (undeployed) air bag assembly outside the vehicle, the deployment
procedure must be followed exactly. Always wear safety glasses during this deployment procedure
until a deployed air bag assembly is scrapped or until an undeployed air bag assembly is shipped.
Before performing the procedures you should be familiar with servicing the SRS and with proper
handling of the air bag assembly. Procedures should be read fully before they are performed.
- The following procedure requires use of J-41434 SRS deployment harness with appropriate
pigtail adapter. Do not attempt procedure without J-41434 adapter.
WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN

PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT HARNESS TO THE DRIVER AIR BAG ASSEMBLY.
DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL
PROCEDURE.
NOTE: This information applies only to driver air bag assembly . Refer to "Deployment Outside
Vehicle (Passenger Air Bag Assembly)" in this section for information on passenger air bag
assembly scrapping.
1. Turn ignition switch to 'LOCK', remove key and put on safety glasses. 2. Inspect J-41434 SRS
Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail adapter is
damaged, discard and obtain
a replacement.
3. Short the two SRS deployment harness leads together by fully seating one banana plug into the
other. SRS deployment harness shall remain
shorted and not be connected to a power source until the air bag is to be deployed.
4. Connect the appropriate pigtail adapter to the SRS deployment harness. 5. Remove the driver
air bag assembly from vehicle.
BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE AIR
BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO
THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT
IN PERSONAL INJURY.
6. Place the driver air bag assembly on a work bench or other surface away from all loose or
flammable objects with its trim cover facing up, away
from the surface.
7. Clear a space on the ground about 183 cm (six feet) in diameter where the driver air bag
assembly is to be deployed. A paved, outdoor location
where there is no activity is preferred. If an outdoor location is not available, a space on the shop
floor where there is no activity and sufficient ventilation is recommended. Ensure no loose or
flammable objects are within the deployment area.
8. Place the driver air bag assembly, with its trim cover facing up, on the ground in the space just
cleared. 9. Stretch the SRS deployment harness and pigtail adapter from the driver air bag
assembly to its full length.
10. Place a power source near the shorted end of the SRS deployment harness. Recommended
application: 12 volts minimum, 2 amps minimum. A
vehicle battery is suggested.
NOTE: Ensure that the pigtail adapter is firmly seated into the driver air bag assembly connector.
Failure to fully seat the connectors may leave the shorting bar located in the driver air bag
assembly connector functioning (shorted) and may result in non~deployment of the driver air bag
assembly.
11. Connect the driver air bag assembly to the pigtail adapter on the SRS deployment harness.
Deployment harness shall remain shorted and not be
connected to a power source until the air bag is to be deployed. The driver air bag assembly will
immediately deploy the air bag when a power source is connected to it.
12. Verify that the area around the driver air bag assembly is clear of all people and loose or
flammable objects. 13. Verify that the driver air bag assembly is resting with its trim cover facing
up. 14. Notify all people in the immediate area that you intend to deploy the driver air bag. The
deployment will be accompanied by a substantial noise
which may startle the uninformed.
15. Separate the two banana plugs on the SRS deployment harness.
NOTE: When the air bag deploys, the driver air bag assembly may jump about 30 cm (one foot)
vertically. This is a normal reaction of the driver air bag to the force of the rapid gas expansion
inside the air bag.
NOTE: When the air bag deploys, the rapid gas expansion will create a substantial report. Notify all
people in the immediate area that you intend to deploy the driver air bag.
WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED

TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY
IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD
ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY.
16. Connect the SRS deployment harness wires to the power source to immediately deploy the
driver air bag. Recommended application: 12 volts
minimum, 2 amps minimum. A vehicle battery is suggested.
17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS
deployment harness leads together by fully seating one banana plug into the other. 19. In the
unlikely event that the driver air bag assembly did not deploy after following these procedures,
proceed immediately with Steps 24 through
26. If the driver air bag assembly did deploy, proceed with Steps 20 through 23.
20. Put on a pair of shop gloves and safety glasses is to protect your hands and eyes from possible
irritation and heat when handling the deployed
driver air bag assembly. After the driver air bag assembly has been deployed, the surface of the air
bag may contain a powdery residue. This power consists primarily of cornstarch (used to lubricate
the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then
quickly reacts with the atmospheric moisture and is converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after
deployment.
WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDING A DEPLOYED

ASSEMBLY WILL BE VERY HOT. ALLOW THE INFLATOR MODULE TO COOL BEFORE
HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE DEPLOYED AIR BAG
ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY
RESULT IN FIRE OR PERSONAL INJURY. AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND SURROUNDING AREAS OF THE DRIVER AIR BAG
ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH THE METAL AREAS OF THE DRIVER AIR
BAG ASSEMBLY FOR ABOUT TEN MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED
DRIVER AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL, WEAR GLOVES AND
HANDLE BY THE AIR BAG OR TRIM COVER.
21. Disconnect the pigtail adapter from the driver air bag assembly as soon after deployment as
possible. This will prevent damage to the pigtail
adapter or SRS deployment harness due to possible contact with the hot driver air bag assembly
canister. The pigtail adapter can be reused. They should, however, be inspected for damage after
each deployment and replaced if necessary.
22. Dispose of the deployed driver air bag assembly through normal refuse channels after it has
cooled for at least 30 minutes. 23. Wash your hands with mild soap and water afterward.
NOTE: The remaining steps are to be followed in the unlikely event that the driver air bag assembly
did not deploy after following these procedures.
24. Ensure that the SRS deployment harness has been disconnected from the power source and
that its two banana plugs have been shorted together by
fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the driver air bag assembly.
WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE
INFLATOR MODULE UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO
THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT
IN PERSONAL INJURY.
26. Temporarily store the driver air bag assembly with its trim cover facing up, away from the
surface upon which it rests.
REMOVAL
1. Disarm SRS as outlined under Technician Safety Information. 2. Remove four bolts attaching air
bag unit to steering wheel. 3. Tilt air bag unit forward and disconnect air bag electrical connector.
Fig. 6 Driver Sir Bag Replacement
4. Remove air bag unit, Fig. 6. Handle air bag unit with cover facing away from body.
INSTALLATION
1. Position air bag unit to steering wheel, then connect all electrical connectors. Ensure connectors
properly engage air bag unit tabs, and that
wiring is properly routed. Support air bag unit in position. Do not allow air bag unit to hang from
electrical wiring or connector.
2. Place air bag unit on steering wheel, Fig. 6, and install attaching bolts. Tighten attaching bolts to
specifications. 3. Connect battery ground cable, then arm SRS as outlined under Technician Safety
Information.
Air Bag: Service and Repair Passenger Air Bag Assembly
Airbag Deployment and Disposal (Inside Vehicle)
Before scrapping an air bag unit or a vehicle with an air bag, the air bag unit should be deployed.
1. Turn ignition Off. 2. Disconnect yellow two-way electrical connector located behind instrument
panel compartment door. 3. Cut air bag unit two-way harness from vehicle harness approximately
six inches from yellow electrical connector. 4. Fabricate two electrical leads at least 30 feet in
length. Use 18 gauge or thicker wire. Splice leads to the cut wires protruding from two-way yellow
SRS electrical connector that was cut from SRS wiring harness.
5. Connect yellow electrical connector to which the 30 foot electrical leads were spliced to the
yellow two-way electrical connector located behind
instrument panel compartment door.
6. Ensure air bag unit is securely mounted to instrument panel. 7. Remove loose objects from
vehicle passenger compartment. 8. Ensure no people, animals or objects are inside or within 30
feet of vehicle. 9. Extend fabricated electrical leads approximately 30 feet away from vehicle, then
connect to fully charged 12 volt battery to deploy air bag unit.
When deploying, ensure vehicle is empty. No poisonous gas is produced upon deployment.
However, do not inhale gas since it could irritate throat and can cause choking. Allow components
to cool for at least ten minutes after deployment. Do not attempt to disassemble air bag module: it
cannot be reused. If air bag did not deploy, consult Isuzu for disposal procedures.
Airbag Deployment and Disposal (Outside Vehicle)
DEPLOYMENT OUTSIDE VEHICLE (PASSENGER AIR BAG ASSEMBLY) -
Deployment outside the vehicle is proper when the vehicle is to be returned to service. This
includes, for example, situations in which the vehicle will be returned to useful service after a
functionally or cosmetically deficient air bag assembly is replaced. Deployment and disposal of a
malfunctioning air bag assembly is, of course, subject to any required retention period.
- For deployment of a live (undeployed) air bag assembly outside the vehicle, the deployment
procedure must be followed exactly. Always wear safety glasses during this deployment procedure
until a deployed air bag assembly is scrapped or until an undeployed air bag assembly is shipped.
Before performing the procedures you should be familiar with servicing the SRS and with proper
handling of the air bag assembly. Procedures should be read fully before they are performed.
- The following procedure requires use of J-41434 SRS deployment harness with appropriate
pigtail adapter. The procedure also requires the use of J-41497 Passenger Side SRS Module
Deployment Fixture. Do not attempt procedure without J-41434 and adapter, and J-41497.
WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN

PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT HARNESS TO THE DRIVER AIR BAG ASSEMBLY.
DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL
PROCEDURE.
NOTE: This information applies only to passenger air bag assembly.
1. Turn ignition switch to 'LOCK', remove key and put on safety glasses. 2. Inspect J-41434 SRS
Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail adapter is
damaged, discard and obtain
a replacement.
3. Short the two SRS deployment harness leads together by fully seating one banana plug into the
other. SRS deployment harness shall remain
shorted and not be connected to a power source until the air bag is to be deployed.
4. Connect the appropriate pigtail adapter to the SRS deployment harness. 5. Remove passenger
air bag assembly from vehicle. 6. Clear a space on the ground approximately 185 cm (six feet) in
diameter where the fixture with attached air bag assembly is to be placed for
deployment. A paved outdoor location where there is no activity is preferred. If an outdoor location
is not available, a space on the shop floor where is no activity and sufficient ventilation is
recommended. Ensure that no loose or flammable objects are within the deployment area.
7. Place the J-41497 on the bench vice. This is necessary to provide sufficient stabilization of the
fixture during deployment. 8. Attach the passenger air bag assembly in the J-41497 air bag
assembly must be mounted such that the bag will deploy upward.
SECURELY HAND-TIGHTEN ALL FASTENERS PRIOR TO DEPLOYMENT.
9. Stretch the SRS Deployment Harness and pigtail adapter from the air bag assembly to its full
length.
10. Place a power source near the shorted end of the SRS deployment harness. (Recommended
application: 12 volts minimum, 2 amps minimum. A
vehicle battery is suggested.)
11. Connect the air bag assembly to the pigtail adapter on the SRS deployment harness. The SRS
Deployment Harness shall remain shorted and not be
connected to a power source until the air bag is to be deployed. The air bag assembly will
immediately deploy the air bag when a power source is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated into the air bag assembly connector. Failure
to fully seat the connectors may leave the shorting bar located in the air bag assembly connector
functioning (shorting the deployment circuit) and may result in non-deployment of the air bag
assembly.
12. Verify that the area around the passenger air bag assembly is clear of all people and loose or
flammable objects. 13. Verify that the passenger air bag assembly is firmly and properly in
J-41497. 14. Notify all people in the immediate area of your intention to deploy the passenger air
bag assembly. The deployment will be accompanied by a
substantial noise which may startle the uninformed.
15. Separate the two banana plugs on the SRS deployment harness.
WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED

TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY
IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD
ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY.
16. Connect the SRS deployment harness wires to the power source to immediately deploy the air
bag assembly. Recommended application : 12 volts
minimum, 2 amps minimum. A vehicle battery is suggested.
17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS
deployment harness leads together by fully seating one banana plug into the other. 19. In the
unlikely event that the passenger air bag assembly did not deploy after following these procedures,
proceed immediately with Steps 24
through 26. If the passenger air bag assembly deployed as intended, proceed with Steps 20
through 23.
20. Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible
irritation and heat when handling the deployed air bag
assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a
powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it
inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is
produced as a by product of the deployment reaction. The sodium hydroxide quickly reacts with the
atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking
soda). Therefore, it is unlikely that sodium hydroxide will be present for very long after deployment.
WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED

ASSEMBLY WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE HANDLING
ANY METAL PORTION OF IT. DO NOT PLACE THE DEPLOYED INFLATOR MODULE NEAR
ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR
PERSONAL INJURY. AFTER AN AIR BAG ASSEMBLY HAS BEEN DEPLOYED, THE METAL
CANISTER AND SURROUNDING AREAS OF THE AIR BAG ASSEMBLY WILL BE HOT. DO
NOT TOUCH THE METAL AREAS OF THE AIR BAG ASSEMBLY FOR ABOUT THIRTY
MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED AIR BAG ASSEMBLY MUST BE MOVED
BEFORE IT IS COOL, WEAR GLOVES AND HANDLE BY THE AIR BAG ITSELF.
21. Disconnect the pigtail adapter from the air bag assembly as soon after deployment as possible
to avoid damage to the pigtail adapter or SRS
deployment harness from contacting the hot air bag assembly canister. The pigtail adapter and
SRS deployment harness are designed to be reused. They should, however, be inspected for
damage after each deployment and replaced if necessary.
22. Dispose of the deployed air bag assembly through normal refuse channels after it has cooled
for at least 30 minutes. 23. Wash your hands with mild soap and water afterward.
NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did
not deploy after following the above procedures.
24. Ensure that the SRS deployment harness has been disconnected from the the power source
and that its two banana plugs have been shorted
together by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the air bag assembly.
BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY.
26. Temporarily store the air bag assembly with the bag facing up, away from the surface upon
which it rests.
Removal
1. Disarm SRS as outlined under Technician Safety Information. 2. On models with manual
transmission, remove shift lever knob and transfer control knob. 3. Remove front console attaching
screws. 4. Disconnect front console electrical connectors, then remove front console. 5. Remove
lower cluster assembly. 6. Remove glove compartment assembly and instrument panel lower
cover. 7. Remove passenger knee bolster reinforcement. 8. Disconnect passenger air bag unit
electrical connector and, where required, the hood release cable.
Passenger Airbag Assembly
9. Remove passenger air bag unit attaching nuts, then air bag unit, Fig. 8.
Installation
Passenger Airbag Assembly
1. Position passenger air bag unit to instrument panel, Fig. 8, and install attaching nuts. Tighten
attaching nuts as listed in Tightening Specifications
chart.
2. Connect air bag unit electrical connector. Ensure connector properly engages unit tabs, and that
wiring is properly routed. 3. Connect hood release cable. 4. Install passenger knee bolster
reinforcement. 5. Install instrument panel lower cover. 6. Install glove compartment assembly. 7.
Install lower cluster assembly. 8. Connect front console electrical connectors, then install front
console. 9. On models with manual transmission, install shift lever knob and transfer control knob.
10. Arm SRS as outlined under Technician Safety Information.

Isuzu Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service Precautions > Electrical Test Equipment
Service Precautions > Electrical Test Equipment > Page 3761
diagnose.
Service Precautions > Page 3762
high side.
value, the SDM
Isuzu Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information >
Technical Service Bulletins > Airbag - On/Off Switch Kit Availability
GROUP: ELECTRICAL

SB98-04-L003)
AFFECTED VEHICLES
AIPDN.
the steering wheel.
from NHTSA.).
PARTS INFORMATION
Isuzu Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information >
Technical Service Bulletins > Airbag - On/Off Switch Kit Availability > Page 3770
Isuzu Workshop Manuals > Restraint Systems > Air Bag Systems > SRS Coil Assembly <--> [Clockspring Assembly / Spiral
Cable, Air Bag] > Component Information > Service Precautions
SRS Coil Assembly: Service Precautions
Cable, Air Bag] > Component Information > Service and Repair > Removal
SRS Coil Assembly: Service and Repair Removal
1. Disarm SRS as outlined under Technician Safety Information. 2. On models with manual
transmission, remove shift lever knob and transfer control knob. 3. Remove front console attaching
screws. 4. Disconnect front console electrical connectors, then remove console. 5. Remove
steering column lower cover, then hood release lever. 6. Place front wheels in straight-ahead
position, then turn ignition to Lock position. 7. Remove air bag unit as outlined under Air Bag Unit,
Replace. 8. Disconnect horn lead, then remove steering wheel to column shaft nut. 9. Place
alignment marks on steering wheel hub and steering shaft.
10. Using puller J-29752, or equivalent, remove steering wheel from shaft. Feed wiring through
steering wheel before removal. 11. Remove steering column cover.
Fig. 9 SRS Coil Assembly & Combination Switch Replacement
12. Disconnect coil assembly and combination switch electrical connectors, Fig. 9. 13. Remove coil
assembly and combination switch attaching screws, then remove coil and complete assembly. Coil
assembly is part of combination
switch. Do not attempt to remove coil from switch.

Cable, Air Bag] > Component Information > Service and Repair > Removal > Page 3776
SRS Coil Assembly: Service and Repair Installation
1. Ensure front wheels are in straight-ahead position and turn ignition to Lock position.
Fig. 9 SRS Coil Assembly & Combination Switch Replacement
2. Position coil assembly and combination switch to steering column, then install attaching screws
and connect electrical connectors, Fig. 9. 3. Install steering column cover. 4. Install steering wheel
and tighten wheel to shaft nut to specifications. 5. Install air bag unit as outlined under Air Bag Unit,
Replace. 6. Install steering column lower cover and hood release lever. 7. Connect front console
electrical connectors, then install console assembly. 8. On models with manual transmission, install
shift lever knob and transfer control knob. 9. Arm SRS as outlined under Technician Safety
Information.
Isuzu Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service Precautions > Electrical Test Equipment
Component Information > Service Precautions > Electrical Test Equipment > Page 3782
diagnose.
high side.
value, the SDM
Isuzu Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping
Undeployed Air Bag
Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 3792

LAW.
Deployed Air Bag
total particulate.
result.
diagnose.
Information > Service Precautions > Page 3797
PRECAUTIONS
signs of damage.
Isuzu Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Child Seat Tether Anchor Kit - Availability
Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor Kit -
Availability
GROUP: MISCELLANEOUS
AVAILABILITY OF CHILD SEAT TETHER ANCHOR KIT
AFFECTED VEHICLES
1999 VehiCROSS (VX) 1992-to current Trooper (UX) 1998-to current Rodeo (UE) 1991-97 Rodeo
(UC) 1996-to current Hombre (TH) 1996-to current Oasis (VO)
SERVICE INFORMATION American Isuzu Motors Inc. is pleased to announce the availability of
Top Tether Child Restraint Seat Anchor Bracket Kits for the above listed Isuzu sport utility vehicles.
The use of this anchor bracket may be necessary when installing certain child seats, which require
anchoring to the vehicle with a top tether strap.
Upon customer's request, these anchor bracket kits may be ordered from AIPDN. Follow the
information outlined in this bulletin for the location of published installation procedures and parts
information for the Top Tether Child Restraint Seat Anchor Bracket Kits.
PARTS INFORMATION
The listed parts are customer pay items.
WARRANTY INFORMATION Isuzu warranty does not cover installation labor.
SERVICE PROCEDURE The anchor bracket installation instructions for the following models are
included with the following applications of Top Tether Child Restraint Seat Anchor Bracket Kits.
- 1999 VehiCROSS (VX)
- 1992-to current Trooper (UX)

- 1998-to current Rodeo (UE)
- 1991-97 Rodeo (UC)
- 1996-to current Hombre (TH)
For the 1996-to current Oasis (VO) models, installation instructions are not included with the Top
Tether Child Restraint Seat Anchor Bracket Kit.
Isuzu Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Child Seat Tether Anchor Kit - Availability > Page 3803
However, information and installation instructions are published in the vehicle Owner's Manual in
"Using Child Seats with Tethers", under Driver and Passenger Safety section.
Additional information regarding the use of the anchor brackets are provided in the Owner's Manual
for the following models:
- 1999 VehiCROSS (VX) Refer to "Child Restraint Anchor Bracket Installation", under Seats, Seat
Belts and Air Bags section.
- 1996-to current Hombre (TH) Refer to "Top Strap", under Seats and Restraint Systems section.
NOTE
Top Tether Child Restraint Seat Anchor Bracket Kits are not applicable to any Amigo models
Isuzu Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat Belt Extender - Availability/Installation Procedure
Technical Service Bulletin # SB95-11-L003 Date: 950401
Seat Belt Extender - Availability/Installation Procedure
ISSUE DATE APRIL 1995
GROUP BODY
SEAT BELT EXTENDER PROGRAM
AFFECTED VEHICLES
All Isuzu passenger and light duty vehicles.
Service Information
The American Isuzu Parts Distribution Network (AIPDN) has announced limited availability of
selected Seat Belt Extenders for Isuzu passenger and light duty vehicles.
To obtain a seat belt extender, a customer must order it using an Isuzu Seat Belt Extender Form.
Dealers are responsible for preparing this form and submitting it to AIPDN.
This Service Bulletin provides dealers with guidance and instructions for preparing and submitting
an Isuzu Seat Belt Extender Form.
Included in this Service Bulletin is AIPDN-AIB-LV07-95, Seat Belt Extenders. This attachment lists
the procedures for filling out an Isuzu Seat Belt Extender Form, measuring a customer for a seat
belt extender, and submitting the form for processing. It further describes what steps AIPDN takes
to process the submitted request, and includes applications, available size, and pricing information,
along with a sample of the form.
Dealer Letter
TO: DEALER PARTS MANAGER
SUBJECT: SEAT BELT EXTENDERS
AIPDN is pleased to announce limited availability of selected "Seat Belt Extenders" for our
passenger cars, light and medium duty trucks. The attachment of this bulletin lists the applications
for each Isuzu model.
Service Bulletins > Seat Belt Extender - Availability/Installation Procedure > Page 3808
To order a "Seat Belt Extender" the customer must first fill Out an Isuzu order form in its entirety. A
sample of this form is also provided with this bulletin. This form contains three copies; the white
copy with the original signature is sent back to AIPDN, the yellow copy is retained by the dealer
and the pink copy is given to the customer.
SEAT BELT EXTENDERS CAN ONLY BE ORDERED ON AN "ISUZU ORDER FORM".
When filling out this seat belt extender order form it is important to emphasize the following
information to your customer:
^ No adult seat belt extender should be specified if the existing belt can accommodate the
customer.
^ Use of an extender, where it is not physically required, significantly increases the potential for a
belt-induced abdominal injury in a severe crash.
^ Only one Seat belt extender per request.
^ The measurement must be performed accurately to ensure that proper restraint performance is
retained with the use of an extender. Applications, available size and pricing information are listed.
^ The seat belt extender must be specified for use by the requester and the seat position in his/her
vehicle.
^ Cost of the seat belt extenders depends upon the vehicle application and belt extender length.
^ The "Isuzu Seat Belt Extender Form" can be requested by calling the Los Angeles Parts
Technical Hotline. (1-310-949-0320, EXT 4785)
Seat Belt Extender Program Procedure
When a dealer receives a customer request for a seat belt extender, it is the dealer's responsibility
to do the following:
Fill out a "Seat Belt Extender" order form which lists:
1. Dealer Code, Dealer Name and Address.
2. Applicant (customers) Name and Address.
3. Vehicle Information (V.I.N.)
4. Measurement Procedures
5. Model/Part Number Information off of original seat belt.
6. Caution Information pertaining to the use of the extender (applicant's signature and date
required)
7. Submit (by mail) the white copy of the seat belt extender form to:
American Isuzu Parts Distribution Network Attn:Parts Technical Expediter/QC Building 2300
Pellissier Place Whittier, Ca 90601
AIPDN'S Responsibility:
Upon receipt of the "Seat Belt Extender Order Form" from a dealer, AIPDN (Parts Technical
Operation Dept.) implements the following procedures:
1. Review the form to ensure that it is filled out properly.
2. Pull the applicable seat belt extender from inventory and fill in the seat belt location, Vehicle
V.I.N. and owners name on the white tag which is affixed to the seat belt extender.
3. The seat belt extender will be given to the PDC and an order will be submitted for the dealer
based on the information listed on the S/B Extender form. The S/B extender number (located in the
upper right hand corner of the form) will be used as the dealer order number.
4. The "white copy" of the dealers seat belt extender form will be retained in the Parts Technical
Operation Dept. At AIPDN (Whittier Ca. Office).
Front Seat Belt Extender Listings
APPLICATION:
PASSENGER CAR LT TRUCK/UTILITY VEHICLES
M/Y VEHICLE M/Y VEHICLE
85-89 I-MARK 81-87 PUP
91-93 STYLUS 88-95 PICKUP (JAPAN)
83-89 IMPULSE 90-94 PICKUP (SIA)
90-92 IMPULSE 89-94 AMIGO 91-95 RODEO 84-91 TROOPER 92-95 TROOPER
AVAILABLE LENGTHS AND PRICING INFORMATION:
LENGTH DLR PRICE MSRP
6" $30.00 $45.00
9" $30.00 $45.00
12" $35.00 $52.00
15" $35.00 $52.00
18" $35.00 $52.00

Isuzu Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch >
Component Information > Technical Service Bulletins > Airbag - On/Off Switch Kit Availability
GROUP: ELECTRICAL

SB98-04-L003)
AFFECTED VEHICLES
AIPDN.
the steering wheel.
from NHTSA.).
PARTS INFORMATION
Isuzu Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch >
Component Information > Technical Service Bulletins > Airbag - On/Off Switch Kit Availability > Page 3816
Isuzu Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc
Player (CD) > CD Changer > Component Information > Technical Service Bulletins > CD Player - Compatible Compact
Discs
CD Changer: Technical Service Bulletins CD Player - Compatible Compact Discs
GROUP: ACCESSORIES
COMPACT DISC (CD) PLAYER/CHANGER AND COMPATIBLE COMPACT DISCS
AFFECTED VEHICLES
All Isuzu vehicles equipped with factory, port, or dealer installed genuine Isuzu CD player or
changer.
SERVICE INFORMATION
With the advent of new technology, some customers may be copying music from other types of
media to CDs. Currently, three types of CDs are available. However, only one of these types is
compatible, and preferred for use, in the CD players/changers used in Isuzu vehicles. Genuine
Isuzu CD players/changers were designed for use with compact discs bearing the Compact Disc
Digital Audio symbol. It is important that the customer always use discs bearing this symbol in their
vehicle's CD player/changer. Discs bearing the Compact Disc Recordable (CD-R) or the Compact
Disc Rewritable (CD-RW) symbols may not play in these CD players/changers
IMPORTANT
In order to prevent damage to the CD player or CD changer units and changer magazine*1 follow
these guidelines:
^ Do not expose any CD or changer magazine*1 to high temperatures or direct sunlight.
^ Do not disassemble the changer magazine*1 or knock it against anything.
^ Insert only CDs with the Compact Disc Digital Audio symbol in the CD player/changer/or changer
magazine*1.
^ Do not stick a label or tape on any CD.
^ Do not use benzene, thinner or any other volatile chemicals on the CD or changer magazine*1
surface.
^ Do not use CDs that have rough edges.
^ Do not use CDs that have different shapes.
^ Do not put foreign substance on the CD or into the CD player/changer.
^ Before inserting the CD, inspect the CD for any tiny fragments or debris.
^ Do not try to insert 2 CDs at the same time.
^ Do not try to insert a CD while the Loading Indicator*2 is off.
NOTE (*1):
If equipped, CD changer units in 1997-earlier Trooper (UX) / Rodeo (UC) models, and all Oasis
(VO) models utilize the CD changer magazine loading system.
NOTE (*2):
If equipped, CD changer units in 1998-later models (except Oasis and Hombre) have a Loading
Indicator to load up to 6 CDs into the unit, one at a time and does not use a changer magazine.
Isuzu Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter <--> [Trailer
Adapter Kit] > Component Information > Technical Service Bulletins > Trailer Wiring Kit - Availability
Trailer Adapter: Technical Service Bulletins Trailer Wiring Kit - Availability
GROUP ACCESSORIES
RODEO (UC) TRAILER HITCH WIRING CONVERTER BOX AVAILABILITY
AFFECTED VEHICLES
All Rodeo (UC) models.
SERVICE INFORMATION
A trailer hitch wiring converter box is now available separately from American Isuzu Parts
Distribution Network (see "Parts Information" section of this Service Bulletin). It can be used for
wiring the 3,500 lb. capacity AIPDN trailer hitch, which is supplied without a converter box. The
converter box can be directly installed to the vehicle harness connector on 1992 and 1993 Rodeo
models. Installation instructions are included with the converter box.
The 4,500 lb. capacity AIPDN trailer hitch kit already includes the converter box.
PARTS INFORMATION
2-90168-201-0 Trailer Hitch Wiring Harness/Converter Box

Adapter Kit] > Component Information > Diagrams > Diagram Information and Instructions
Trailer Adapter: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Adapter Kit] > Component Information > Diagrams > Diagram Information and Instructions > Page 3831

Trailer Adapter: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Trailer Adapter: Electrical Diagrams
Trailer Adapter
Trailer Adapter
Isuzu Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Doors: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup
& Damage
Doors: All Technical Service Bulletins Front Door/Fender - Ice Buildup & Damage
ISSUE DATE FEBRUARY 1996
GROUP BODY
RODEO (UC), PICKUP (TF), AND AMIGO (TC) ICE BUILDUP FRONT DOOR/FENDER DAMAGE
APPLICABLE VEHICLES
Rodeo (UC), Pickup (TF), and Amigo (TC) models.
SERVICE INFORMATION
On some affected vehicles, in cold weather conditions, water can become trapped in the front
fender well and freeze, forming a buildup of ice around the lower portion of the door-to-fender area.
When the driver or front passenger door is opened, this ice buildup can damage the door and/or
fender.
To correct the problem, replace the existing right and left fender inner liner with the appropriate
new, improved fender inner liner (see "Parts Information" section of this Service Bulletin) using the
procedure described in this Service Bulletin. The new fender inner liner diverts water away from the
lower portion of the front door-to-fender area, so that in cold weather, this area is kept free from ice
buildup.
SERVICE PROCEDURE
REMOVAL
1. Front Mud Flap (If Equipped) (Right/Left) and/or Running Board (If Equipped - Rodeo Only)
(Right/Left)
^ Remove front mud flap and/or corner of running board.
2. Fender Inner Liner (Right/Left)

^ Remove in accordance with Section 2C of appropriate Workshop Manual.
INSTALLATION
^ Install appropriate new fender inner liner (see "Parts Information" section) in accordance with
Section 2C of appropriate Workshop Manual.
(Right/Left)
^ Install front mud flap and/or corner of running board.
PARTS INFORMATION
* These parts apply only to vehicles equipped with 31 X 10.5R15 or P245/70R16 tires.
& Damage > Page 3863

Use the published labor operations. If vehicle is equipped with front mud flaps and/or running
boards, use appropriate add times shown.
3. Front Sill Plate (Right)
^ Lay down carpet and install right front sill plate.

& Damage > Page 3864
4. No. 1 Cab Mounting (Right) - Nut
^ Torque 10 mm body mounting nut to 50 Nm (37 ft. lbs.)
PARTS INFORMATION
8-94223-176-0 Washer; Body 1
Mounting Rubber
Use the published labor operation:

Service Bulletins > Customer Interest for Doors: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage
Doors: Customer Interest Front Door/Fender - Ice Buildup & Damage
GROUP BODY
APPLICABLE VEHICLES
SERVICE INFORMATION
fender.
buildup.
SERVICE PROCEDURE
REMOVAL
(Right/Left)

INSTALLATION
(Right/Left)
PARTS INFORMATION
Service Bulletins > Customer Interest for Doors: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage >
Page 3870


Service Bulletins > Customer Interest for Doors: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage >
Page 3871
PARTS INFORMATION
8-94223-176-0 Washer; Body 1
Mounting Rubber

Isuzu Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Diagrams > Diagram Information and Instructions
Power Trunk / Liftgate Lock Actuator: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 3877

Power Trunk / Liftgate Lock Actuator: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Power Trunk / Liftgate Lock Actuator: Electrical Diagrams
Tailgate Glass Release

Tailgate Glass Release
Isuzu Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Latch: >
SB96-11-L007 > Sep > 96 > Rear Hatchgate - Glass Difficult To Latch
Trunk / Liftgate Latch: All Technical Service Bulletins Rear Hatchgate - Glass Difficult To Latch
GROUP: BODY
1991-95.5 RODEO (UC) REAR HATCHGATE GLASS DIFFICULT TO LATCH
AFFECTED MODELS
1991-95.5 Rodeo (UC) models.
SERVICE INFORMATION
Some affected vehicles may experience a condition in which the rear hatchgate glass may be
difficult to latch. This condition may be caused by a broken actuator spring in the hatchgate lock
actuator assembly.
To correct this condition, replace the actuator spring in the hatchgate lock actuator assembly with a
new actuator spring (Part No. 8-97138-290-0) using the procedure described in this Service
Bulletin.
SERVICE PROCEDURE
REMOVAL
1. Tailgate Trim Panel & Left Side Inner Cover (Figure 1)
^ Remove two panel screws on each side of hatch lock.
^ Pull off trim panel.
^ Remove seven screws from left side inner cover and remove cover.
SB96-11-L007 > Sep > 96 > Rear Hatchgate - Glass Difficult To Latch > Page 3907
2. Hatchgate Lock Actuator Assembly (Figure 2)
^ Cut sealing adhesive with razor blade and peel back waterproof sheet.
^ Remove two bolts holding hatchgate lock actuator assembly to tailgate.
^ Disconnect actuator rod, detach wire harness clip, remove hatchgate lock actuator assembly, and
disconnect connector.
3. Actuator Spring (Figure 3)
^ Remove actuator spring from hatch-gate lock actuator assembly.
INSTALLATION
^ Install new actuator spring (Part No. 8-97138-290-0) to hatchgate lock actuator assembly.
SB96-11-L007 > Sep > 96 > Rear Hatchgate - Glass Difficult To Latch > Page 3908
^ Connect actuator connector and wire harness clip to hatchgate lock actuator assembly.
^ Position hatchgate lock actuator assembly onto tailgate and secure with two bolts. Connect
actuator rod to hatchgate lock actuator assembly.
^ Install waterproof sheet to tailgate. Reseal sheet by pressing down on sealing adhesive.
3. Tailgate Left Side Inner Cover and Trim Panel (Figure 1)
^ Position inner cover onto tailgate and secure with screws.
^ Position trim panel onto tailgate and press clips into place.
^ Install screws on each side of hatch lock.
^ Check for proper hatchgate glass latching operation.
PARTS INFORMATION
8-97138-290-0 Spring; Actuator 1
Labor time includes 0.1 administration allowance.

Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Latch: > SB96-11-L007 > Sep
> 96 > Rear Hatchgate - Glass Difficult To Latch
Trunk / Liftgate Latch: Customer Interest Rear Hatchgate - Glass Difficult To Latch
GROUP: BODY
1991-95.5 RODEO (UC) REAR HATCHGATE GLASS DIFFICULT TO LATCH
AFFECTED MODELS
1991-95.5 Rodeo (UC) models.
SERVICE INFORMATION
Some affected vehicles may experience a condition in which the rear hatchgate glass may be
difficult to latch. This condition may be caused by a broken actuator spring in the hatchgate lock
actuator assembly.
To correct this condition, replace the actuator spring in the hatchgate lock actuator assembly with a
new actuator spring (Part No. 8-97138-290-0) using the procedure described in this Service
Bulletin.
SERVICE PROCEDURE
REMOVAL
1. Tailgate Trim Panel & Left Side Inner Cover (Figure 1)
^ Remove two panel screws on each side of hatch lock.
^ Pull off trim panel.
^ Remove seven screws from left side inner cover and remove cover.
> 96 > Rear Hatchgate - Glass Difficult To Latch > Page 3914
^ Cut sealing adhesive with razor blade and peel back waterproof sheet.
^ Remove two bolts holding hatchgate lock actuator assembly to tailgate.
^ Disconnect actuator rod, detach wire harness clip, remove hatchgate lock actuator assembly, and
disconnect connector.
^ Remove actuator spring from hatch-gate lock actuator assembly.
INSTALLATION
^ Install new actuator spring (Part No. 8-97138-290-0) to hatchgate lock actuator assembly.
> 96 > Rear Hatchgate - Glass Difficult To Latch > Page 3915
^ Connect actuator connector and wire harness clip to hatchgate lock actuator assembly.
^ Position hatchgate lock actuator assembly onto tailgate and secure with two bolts. Connect
actuator rod to hatchgate lock actuator assembly.
^ Install waterproof sheet to tailgate. Reseal sheet by pressing down on sealing adhesive.
3. Tailgate Left Side Inner Cover and Trim Panel (Figure 1)
^ Position inner cover onto tailgate and secure with screws.
^ Position trim panel onto tailgate and press clips into place.
^ Install screws on each side of hatch lock.
^ Check for proper hatchgate glass latching operation.
PARTS INFORMATION
8-97138-290-0 Spring; Actuator 1
Labor time includes 0.1 administration allowance.

Isuzu Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fender: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage
Fender: All Technical Service Bulletins Front Door/Fender - Ice Buildup & Damage
GROUP BODY
APPLICABLE VEHICLES
SERVICE INFORMATION
fender.
buildup.
SERVICE PROCEDURE
REMOVAL
(Right/Left)

INSTALLATION
(Right/Left)
PARTS INFORMATION
Technical Service Bulletins for Fender: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage > Page
3924


Technical Service Bulletins for Fender: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage > Page
3925
PARTS INFORMATION
8-94223-176-0 Washer; Body 1
Mounting Rubber

Isuzu Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > Customer
Interest for Fender: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage
Fender: Customer Interest Front Door/Fender - Ice Buildup & Damage
GROUP BODY
APPLICABLE VEHICLES
SERVICE INFORMATION
fender.
buildup.
SERVICE PROCEDURE
REMOVAL
(Right/Left)

INSTALLATION
(Right/Left)
PARTS INFORMATION
Interest for Fender: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage > Page 3931


Interest for Fender: > SB96-11-L002 > Feb > 96 > Front Door/Fender - Ice Buildup & Damage > Page 3932
PARTS INFORMATION
8-94223-176-0 Washer; Body 1
Mounting Rubber

Isuzu Workshop Manuals > Body and Frame > Frame > Trailer Adapter <--> [Trailer Adapter Kit] > Component Information >
Technical Service Bulletins > Trailer Wiring Kit - Availability
Trailer Adapter: Technical Service Bulletins Trailer Wiring Kit - Availability
GROUP ACCESSORIES
RODEO (UC) TRAILER HITCH WIRING CONVERTER BOX AVAILABILITY
AFFECTED VEHICLES
SERVICE INFORMATION
A trailer hitch wiring converter box is now available separately from American Isuzu Parts
Distribution Network (see "Parts Information" section of this Service Bulletin). It can be used for
wiring the 3,500 lb. capacity AIPDN trailer hitch, which is supplied without a converter box. The
converter box can be directly installed to the vehicle harness connector on 1992 and 1993 Rodeo
models. Installation instructions are included with the converter box.
The 4,500 lb. capacity AIPDN trailer hitch kit already includes the converter box.
PARTS INFORMATION
2-90168-201-0 Trailer Hitch Wiring Harness/Converter Box

Diagrams > Diagram Information and Instructions
Trailer Adapter: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Diagrams > Diagram Information and Instructions > Page 3940

Trailer Adapter: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Trailer Adapter: Electrical Diagrams
Trailer Adapter
Trailer Adapter
Isuzu Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Radiator
Grilles - Painting of Primered Replacement
Grille: Technical Service Bulletins Radiator Grilles - Painting of Primered Replacement
GROUP: BODY
1993-97 RODEO (UC) AND 1998 RODEO (UE) PAINTING OF PRIMERED REPLACEMENT
RADIATOR GRILLES
APPLICABLE VEHICLES
1993-97 Rodeo (UC) and 1998 Rodeo (UE) models.
SERVICE INFORMATION
The American Isuzu Parts Distribution Network (AIPDN) has announced that it will phase out its
entire inventory of colored replacement radiator grilles, and once depleted, will supply only
primered replacement radiator grilles.
AIPDN will continue to fill colored replacement radiator grille orders for 1993-97 Rodeo (UC) model
applications as long as stock of that particular color is available. If stock of that color has been
depleted, the requester will receive a primered replacement radiator grille.
For 1998 Rodeo (UE) model applications, AIPDN will supply only primered replacement radiator
grilles. These primered replacement radiator grilles will be available from AIPDN at vehicle start of
sale.
All primered replacement radiator grilles should be prepared and finished with a high-quality
basecoat and clearcoat, in accordance with the paint manufacturer's instructions.
Refer to Parts Bulletin AIPDN-PTS-LV14-97 for details and further information regarding AIPDN
phaseout of colored replacement radiator grilles.
Use published Flat Rate Manual labor operation number 210701 for painting replacement radiator
grilles.
Isuzu Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping
Undeployed Air Bag
and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping > Page 3972

LAW.
Deployed Air Bag
total particulate.
result.
diagnose.
and Disarming > System Information > Service Precautions > Page 3977
PRECAUTIONS
signs of damage.
Isuzu Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins
> All Technical Service Bulletins: > SB99-11-S001 > Jan > 99 > Rear Door - Will Not Open From the Inside or Outside
Door Locks: All Technical Service Bulletins Rear Door - Will Not Open From the Inside or Outside
ISSUE DATE: JANUARY 1999
GROUP: BODY
1991-96 RODEO (UC) REAR DOOR CANNOT BE OPENED: RUSTED REAR DOOR LOCK
ASSEMBLY
AFFECTED VEHICLES Certain 1991-96 Rodeo (UC) models.
SERVICE INFORMATION
Condition: The rear door may not be opened from the inside or outside, regardless of the door lock
position (lock/unlock). When this occurs, the technician cannot remove the interior door panel, in
order to access the rear door lock assembly.
Possible Cause: The rear door lock assembly may be seized due to rusting from water intrusion
through the outer waist seal. When this occurs, the latch mechanism cannot operate the release
arm.
Correction: To correct this condition, follow the procedures outlined in this bulletin to open the rear
door with the seized lock assembly, and replace the rear door lock assembly using the procedure
outlined in the Workshop Manual.
SERVICE PROCEDURE
1. Fabricate a tool for opening the rear door that cannot be opened.
^ This tool can be fabricated with a (1/8" diameter thickness) solid steel rod or equivalent (such as
an antenna mast).
^ All bends must be 90° and the length of each bend should approximate the specifications in the
illustration. (Figure 1)
> All Technical Service Bulletins: > SB99-11-S001 > Jan > 99 > Rear Door - Will Not Open From the Inside or Outside >
Page 3987
2. Once the tool is fabricated and readied for use, lift the outside handle of the affected rear door
and insert the small end of the tool through the opening created by the handle hinge nearest to the
door striker. (Figure 2)
3. With the terminating end of the tool facing the rear door lock assembly, probe the tool to locate
the bottom of the release lever on the rear door lock assembly. (Figure 3)
> All Technical Service Bulletins: > SB99-11-S001 > Jan > 99 > Rear Door - Will Not Open From the Inside or Outside >
Page 3988
4. Once the bottom of the release lever is located, push the tool up to move the release lever and
to open the door. This may take several attempts. (Figure 4)
^ Since the release lever is spring loaded, it may require a firm push.
^ Do not over-power the tool. It may deform or cause damage to the door lock linkages.
^ If the door lock assembly is heavily corroded, soak the rear door lock assembly through the
access hole with spray-on penetrating oil for a few minutes to facilitate the movement of the
release lever.
5. Once the door is opened, it will allow the removal of the interior door panel. Follow the
procedures outlined in the appropriate published Workshop Manual for removing the door panel
and replacing the rusted rear door lock assembly.
6. If the old door lock assembly was heavily corroded due to water intrusion, inspect the outer waist
seal between the fixed door window glass and the exterior door panel for excessive clearance.
7. If necessary, remove the seal and apply room temperature vulcanizing (RTV) rubber sealant to
seal the gap, then reinstall the seal.
8. When installing a new rear door lock assembly, apply a coat of lithium grease (or spray type) to
prevent future corrosion.
PARTS INFORMATION
PART NUMBER DESCRIPTION QUANTITY REQUIRED
8-94330-593-5 LOCK; Door, Rear (Left) 1*
8-94330-592-5 LOCK; Door, Rear (Right) 1*
*Replace as required
Use the published labor operation as shown.
Labor Time includes administrative time allowance.

> All Technical Service Bulletins: > SB9411006 > Oct > 94 > Power Door Locks - Owner Manual Clarification
Door Locks: All Technical Service Bulletins Power Door Locks - Owner Manual Clarification
ISSUE DATE OCTOBER 1994
GROUP BODY
1993 RODEO (UC) POWER DOOR LOCK OPERATION (Owner's Manual Clarification)
AFFECTED VEHICLES
1993 Rodeo (UC) models equipped with power door locks.
SERVICE INFORMATION
Power door lock operation is incorrectly described on page 4-5 of the 1993 Rodeo (UC) Owner's
Manual (Publication No, AIMI-SVC-238, included in Glovebox Packet part No. 2-90993-071-0).
The correct Owner's Manual description is as follows:
[C] POWER DOOR LOCKS (If so equipped)
Locking or unlocking the driver's door with either the key or the lock button will also lock or unlock
the remaining doors. Locking or unlocking the front passenger's door with the key will not lock or
unlock the remaining doors.
As noted in the above corrected description, locking or unlocking the passenger door with the key
will NOT operate the other doors.
> Customer Interest: > SB99-11-S001 > Jan > 99 > Rear Door - Will Not Open From the Inside or Outside
Door Locks: Customer Interest Rear Door - Will Not Open From the Inside or Outside
ISSUE DATE: JANUARY 1999
GROUP: BODY
1991-96 RODEO (UC) REAR DOOR CANNOT BE OPENED: RUSTED REAR DOOR LOCK
ASSEMBLY
AFFECTED VEHICLES Certain 1991-96 Rodeo (UC) models.
SERVICE INFORMATION
Condition: The rear door may not be opened from the inside or outside, regardless of the door lock
position (lock/unlock). When this occurs, the technician cannot remove the interior door panel, in
order to access the rear door lock assembly.
Possible Cause: The rear door lock assembly may be seized due to rusting from water intrusion
through the outer waist seal. When this occurs, the latch mechanism cannot operate the release
arm.
Correction: To correct this condition, follow the procedures outlined in this bulletin to open the rear
door with the seized lock assembly, and replace the rear door lock assembly using the procedure
outlined in the Workshop Manual.
SERVICE PROCEDURE
1. Fabricate a tool for opening the rear door that cannot be opened.
^ This tool can be fabricated with a (1/8" diameter thickness) solid steel rod or equivalent (such as
an antenna mast).
^ All bends must be 90° and the length of each bend should approximate the specifications in the
illustration. (Figure 1)
> Customer Interest: > SB99-11-S001 > Jan > 99 > Rear Door - Will Not Open From the Inside or Outside > Page 3998
2. Once the tool is fabricated and readied for use, lift the outside handle of the affected rear door
and insert the small end of the tool through the opening created by the handle hinge nearest to the
door striker. (Figure 2)
3. With the terminating end of the tool facing the rear door lock assembly, probe the tool to locate
the bottom of the release lever on the rear door lock assembly. (Figure 3)
> Customer Interest: > SB99-11-S001 > Jan > 99 > Rear Door - Will Not Open From the Inside or Outside > Page 3999
4. Once the bottom of the release lever is located, push the tool up to move the release lever and
to open the door. This may take several attempts. (Figure 4)
^ Since the release lever is spring loaded, it may require a firm push.
^ Do not over-power the tool. It may deform or cause damage to the door lock linkages.
^ If the door lock assembly is heavily corroded, soak the rear door lock assembly through the
access hole with spray-on penetrating oil for a few minutes to facilitate the movement of the
release lever.
5. Once the door is opened, it will allow the removal of the interior door panel. Follow the
procedures outlined in the appropriate published Workshop Manual for removing the door panel
and replacing the rusted rear door lock assembly.
6. If the old door lock assembly was heavily corroded due to water intrusion, inspect the outer waist
seal between the fixed door window glass and the exterior door panel for excessive clearance.
7. If necessary, remove the seal and apply room temperature vulcanizing (RTV) rubber sealant to
seal the gap, then reinstall the seal.
8. When installing a new rear door lock assembly, apply a coat of lithium grease (or spray type) to
prevent future corrosion.
PARTS INFORMATION
PART NUMBER DESCRIPTION QUANTITY REQUIRED
8-94330-593-5 LOCK; Door, Rear (Left) 1*
8-94330-592-5 LOCK; Door, Rear (Right) 1*
*Replace as required
Use the published labor operation as shown.
Labor Time includes administrative time allowance.

> All Other Service Bulletins for Door Locks: > SB97-01-L003 > Jun > 97 > Spark Plug Tube - Oil Seepage
GROUP: ENGINE
AFFECTED VEHICLES
SERVICE PROCEDURE
SB96-01-L005, issued 9/96.
authorized repair.
> All Other Service Bulletins for Door Locks: > SB96-01-L005 > Sep > 96 > Spark Plug Tube - Oil Accumulation
GROUP: ENGINE
ACCUMULATION
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
PARTS INFORMATION
8-97163-999-0 High Tension 4
8-97164-006-0 High Tension 1
set.
Isuzu Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
Power Door Lock Actuator: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Power Door Lock Actuator: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Power Door Lock Actuator: Electrical Diagrams

Power Door Locks: Automatic
Power Door Locks: Automatic

Isuzu Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Color Codes & Cross References
Paint: Technical Service Bulletins Paint - Color Codes & Cross References
ISSUE DATE August 13, 1992
GROUP BODY
1993 PAINT COLORS AND CODES
VEHICLES AFFECTED
All 1993 Isuzu passenger cars and trucks.
SERVICE INFORMATION
This Service Bulletin contains paint codes for 1993 Isuzu vehicle colors. Refer to Service Bulletin
SB90-11-007 for paint codes for 1986-1991 vehicle colors; refer to SB91-11-005 for 1992 paint
codes.
In Chart 1, the option codes and colors are listed by vehicle model, with a reference to paint code.
The paint code is used in Chart 2 to identify the aftermarket paint vendor code.
On the vehicle, the option code is printed on the Service ID Plate, located under the hood, on the
bulkhead at the rear of the engine compartment.
All aftermarket paint cross-reference information has been supplied by the paint manufacturers. In
many cases, the aftermarket manufacturer's color name differs from the Isuzu color name listed in
this Service Bulletin.
The last column in Chart 2 indicates whether or not the paint should be clear-coated. If a 2-tone
vehicle uses one clear-coat color and one uncoated color, only the clear-coated color receives the
clear coat.
IMPORTANT Due to differences in manufacturing plants, be sure to specify the manufacturing

plant when ordering paint. The color name is the same, but the paint formula differs between
assembly plants. Check the VIN plate to verify where the vehicle was manufactured:
^ Pickups with VINs starting with JAA were manufactured in Japan.
^ Pickups and Rodeos with VINs starting with 4S1 or 4S2 were manufactured at SIA. Give this
information to your paint supplier to ensure receiving the exact formula required.
Bulletins > Paint - Color Codes & Cross References > Page 4050
CHART 1
Bulletins > Paint - Color Codes & Cross References > Page 4051
CHART 2
Isuzu Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Luggage Rack: > SB96-13-L005 > Oct > 96 >
Roof Rack - New Installation Tool Available
Luggage Rack: All Technical Service Bulletins Roof Rack - New Installation Tool Available
ISSUE DATE: OCTOBER 1996
GROUP: ACCESSORIES
1991-97 RODEO (UC) AERO ROOF RACK NEW INSTALLATION TOOL AVAILABILITY
AFFECTED VEHICLES
1991-97 Rodeo (UC) models
SERVICE INFORMATION
A new, more durable tool is currently available from Liberty Engineering, which makes rivet nut
installation easier when installing the Aero Roof Rack Kit (Part No. 2-90122-300-6). To order this
new tool, contact:
Liberty Engineering 9648 Eton Avenue Chatsworth, CA 91311 Phone: 818-786-8111 FAX:
818-786-8222
Ask for Part No. C-845-2520, Rivnut(R) Fastener Header. Be sure to specify the rivet nut thread
size (1/4"-20) when ordering.
At the time this Service Bulletin was published, Liberty Engineering was charging $35.00 for this
tool, plus shipping and handling. Contact Liberty Engineering for current pricing.
Follow the instructions packaged with the tool to ensure proper tool usage.
Information > Technical Service Bulletins > All Technical Service Bulletins for Luggage Rack: > 9411005 > Jul > 94 > Roof
Rack - Howling Noise at Highway Speeds
Luggage Rack: All Technical Service Bulletins Roof Rack - Howling Noise at Highway Speeds
GROUP BODY
RODEO (UC) ROOF RACK WIND NOISE
AFFECTED VEHICLES
1993 Rodeo (UC) models equipped with a roof rack.
SERVICE INFORMATION
Some affected vehicles may experience an audible howling noise coming from the rear center of
the vehicle roof when the vehicle is traveling at highway speeds. To eliminate this condition,
replace the existing front and rear cross bar inserts with the new improved crossbar insert listed in
the "Parts Information" section, as described in this Service Bulletin.
SERVICE PROCEDURE
1. Remove the holding screws that secure the ends of the cross bar insert to the two stanchions
(Figure 1). Repeat this step for the other cross bar.
Information > Technical Service Bulletins > All Technical Service Bulletins for Luggage Rack: > 9411005 > Jul > 94 > Roof
Rack - Howling Noise at Highway Speeds > Page 4065
2. Press the release button on one of the stanchions and slide the stanchion earlier forward or
backward on its slide rail until the end of the cross bar insert frees the stanchion. Remove the cross
bar insert (Figure 2). Repeat this step for the other cross bar insert.
3. Slip the ends of the new cross bar insert into each of the two stanchions and reinstall the two
holding screws (Figure 3). Repeat this step for the other new cross bar insert.
4. Adjust the cross bars on the slide rails, as desired.
PARTS INFORMATION
2-90122-002-0 Cross Bar Insert 2
Use the existing labor operation:

Information > Technical Service Bulletins > All Technical Service Bulletins for Luggage Rack: > SB9411005 > Jul > 94 >
Roof Rack - Wind Noise
Luggage Rack: All Technical Service Bulletins Roof Rack - Wind Noise
GROUP BODY
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
2. Press the release button on one of the stanchions and slide the stanchion either forward or
Information > Technical Service Bulletins > All Technical Service Bulletins for Luggage Rack: > SB9411005 > Jul > 94 >
Roof Rack - Wind Noise > Page 4070
PARTS INFORMATION


Information > Technical Service Bulletins > Customer Interest: > 9411005 > Jul > 94 > Roof Rack - Howling Noise at
Highway Speeds
Luggage Rack: Customer Interest Roof Rack - Howling Noise at Highway Speeds
GROUP BODY
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
Information > Technical Service Bulletins > Customer Interest: > 9411005 > Jul > 94 > Roof Rack - Howling Noise at
Highway Speeds > Page 4076
2. Press the release button on one of the stanchions and slide the stanchion earlier forward or
PARTS INFORMATION
Use the existing labor operation:

Information > Technical Service Bulletins > Customer Interest: > SB9411005 > Jul > 94 > Roof Rack - Wind Noise
Luggage Rack: Customer Interest Roof Rack - Wind Noise
GROUP BODY

AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
2. Press the release button on one of the stanchions and slide the stanchion either forward or
Information > Technical Service Bulletins > Customer Interest: > SB9411005 > Jul > 94 > Roof Rack - Wind Noise > Page
4081
PARTS INFORMATION


Information > Technical Service Bulletins > All Other Service Bulletins for Luggage Rack: > SB96-13-L005 > Oct > 96 >
Roof Rack - New Installation Tool Available
Luggage Rack: All Technical Service Bulletins Roof Rack - New Installation Tool Available
ISSUE DATE: OCTOBER 1996
GROUP: ACCESSORIES
1991-97 RODEO (UC) AERO ROOF RACK NEW INSTALLATION TOOL AVAILABILITY
AFFECTED VEHICLES
1991-97 Rodeo (UC) models
SERVICE INFORMATION
A new, more durable tool is currently available from Liberty Engineering, which makes rivet nut
installation easier when installing the Aero Roof Rack Kit (Part No. 2-90122-300-6). To order this
new tool, contact:
Liberty Engineering 9648 Eton Avenue Chatsworth, CA 91311 Phone: 818-786-8111 FAX:
818-786-8222
Ask for Part No. C-845-2520, Rivnut(R) Fastener Header. Be sure to specify the rivet nut thread
size (1/4"-20) when ordering.
At the time this Service Bulletin was published, Liberty Engineering was charging $35.00 for this
tool, plus shipping and handling. Contact Liberty Engineering for current pricing.
Follow the instructions packaged with the tool to ensure proper tool usage.
Isuzu Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Technical Service Bulletins >
Tailgate - Rattle Noise Diagnosis & Repair
Spare Tire Carrier: Technical Service Bulletins Tailgate - Rattle Noise Diagnosis & Repair
GROUP BODY
RODEO (UC) RATTLE NOISE FROM TAILGATE AREA
AFFECTED VEHICLES
All 1991-92 Rodeo (UC) models.
SERVICE INFORMATION
Sonic affected vehicles may experience a rattling noise coming from the tailgate area.
On models equipped with inside spare tire carrier, the noise could be caused by:
^ Incorrect tailgate door striker alignment.
^ Insufficient insulation between the tailgate door and the body.
^ Insufficient insulation between hatch glass and tailgate.
On models equipped with outside spare tire carrier, the noise could be caused by:
^ Insufficient insulation between tailgate door and body.
^ Worn bushings on spare tire carrier hinges.
^ Loose spare tire carrier bracket fixing bolts.
^ (Vehicles produced before 6/91 only) Spare tire carrier release lever contacting the carrier.
This Service Bulletin describes repair procedures for eliminating the above conditions.
SERVICE PROCEDURE
Test drive the vehicle to identify the source of the rattling noise. Depending on the source of the
noise, correct the condition as follows:
1. Lower tailgate door rattle (light metallic sound):
a. Check alignment of lower tailgate door and rear fender. If the door and fender are not flush,
adjust tailgate door striker alignment as described in the appropriate Workshop Manual.
b. Refer to Service Bulletin SB92-11-009 (issued 7/20/92) for instructions on installing tubing in the
tailgate weatherstrip on both sides of the door.
2. Upper hatch glass rattle against tailgate door. Repair the tailgate waist seal (top of tailgate door)
on both sides (Figure 1) as follows:
a. Cut two 6" lengths of tubing (11/32" outside diameter).
b. Locate the existing vent hole in the waist seal.

Tailgate - Rattle Noise Diagnosis & Repair > Page 4091
c. Install the tubing, sliding it into the waist seal. Position the tubing as shown in Figure 1. Take
care to prevent damaging the waist seal.
Note: Steps 3, 4 and 5 below apply only to models equipped with outside spare tire carrier.
3. Spare tire carrier hinge rattle (heavy metallic sound):
Refer to Service Bulletin SB92-11-012 (issued 9/24/92) for spare tire carrier hinge repair
procedures.
4. Spare tire carrier bracket rattle:

Tailgate - Rattle Noise Diagnosis & Repair > Page 4092
Torque the six spare tire carrier bracket fixing bolts (Figure 2) to 34 +/- 5 ft.lbs.
5. Spare tire carrier release lever rattle:
Refer to Service Bulletin SB91-11-006 (issued 6/13/91) for instructions on installing a rubber
cushion to the spare tire carrier lever.

Isuzu Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service
Bulletins > Tailgate - Rattle Noise Diagnosis & Repair
Tailgate Hinge: Technical Service Bulletins Tailgate - Rattle Noise Diagnosis & Repair
GROUP BODY
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE

Bulletins > Tailgate - Rattle Noise Diagnosis & Repair > Page 4098
procedures.


Isuzu Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Technical Service
Bulletins > Tailgate - Rattle Noise Diagnosis & Repair
Tailgate Latch: Technical Service Bulletins Tailgate - Rattle Noise Diagnosis & Repair
GROUP BODY
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE

procedures.


Isuzu Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments
Cruise Control Servo Cable: Adjustments
1. Position accelerator pedal so engine runs at normal idling speed.
Fig. 18 Actuator cable adjustment
2. Loosen nuts A and B, Fig. 5. 3. Pull outer cable toward accelerator pedal, ensuring there is no
play in the inner cable at this time. 4. Turn nut A until contact is made with the bracket, then tighten.
5. Tighten nut B to lock actuator side cable in position.
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Audible Warning Device: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Audible Warning Device: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Audible Warning Device: Electrical Diagrams
Seat Belt, Lights-On, And Key-In Ignition Warning System

Seat Belt, Lights-On, And Key-In Ignition Warning System
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Brake Warning Indicator: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Brake Warning Indicator: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Brake Warning System
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
Cigarette Lighter: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Cigarette Lighter: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Cigarette Lighter
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping
Undeployed Air Bag
Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping >
Page 4192
LAW.
Deployed Air Bag
total particulate.
Page 4193
Page 4194
Page 4195
result.
Page 4196
diagnose.
Arming and Disarming > System Information > Service Precautions > Page 4197
PRECAUTIONS
signs of damage.
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection > Quick Check
Fuel Gauge: Testing and Inspection Quick Check

Testing and Inspection > Quick Check > Page 4202
Fuel Gauge: Testing and Inspection Diagnosis By Symptom
Fig. 12 Fuel Gauge Diagnosis: Needle Does Not Move
Refer to Fig. 12, for fuel gauge diagnosis.
Needle Does Not Reach 'F'

Fig. 13 Fuel Gauge Diagnosis: Needle Does Not Reach "F"
Needle Goes Past 'F'

Fig. 14 Fuel Gauge Diagnosis: Needle Goes Past "F"

Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component

Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service Precautions > Air Bag Assembly Handling/Shipping/Scrapping
Undeployed Air Bag
Page 4213
LAW.
Deployed Air Bag
total particulate.
Page 4214
Page 4215
Page 4216
result.
Page 4217
diagnose.
Arming and Disarming > System Information > Service Precautions > Page 4218
PRECAUTIONS
signs of damage.
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Diagrams > Diagram Information and Instructions
Instrument Panel Bulb: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
Panel Bulb > Component Information > Diagrams > Diagram Information and Instructions > Page 4223

Instrument Panel Bulb: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Instrument Panel Bulb: Electrical Diagrams

Dash And Console Lights
Dash And Console Lights

Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Information > Technical Service Bulletins > Low Fuel Warning Unit - Manual Correction
Low Fuel Lamp/Indicator: Technical Service Bulletins Low Fuel Warning Unit - Manual Correction
GROUP ELECTRICAL
LOW FUEL WARNING UNIT INSPECTION (WORKSHOP MANUAL CORRECTION)
AFFECTED VEHICLES
1988-93 Pickup (TF), 1989-93 Amigo (TC), 1991-93 Rodeo (UC), 1990-92 Impulse (JI), 1991-93
Stylus (JS) models.
SERVICE INFORMATION
Inspection procedures for the low fuel warning unit are incorrectly described in the Workshop
Manuals. See illustration.
Information > Technical Service Bulletins > Low Fuel Warning Unit - Manual Correction > Page 4249
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oxygen Sensor ( O2 ) Lamp <-->
[Maintenance Required Lamp/Indicator] > Component Information > Service and Repair
Oxygen Sensor ( O2 ) Lamp: Service and Repair
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component

PURPOSE
LOCATION
OPERATION

Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - A/T >
CIRCUIT DESCRIPTION
CIRCUIT DESCRIPTION
257°F (125°C).
CIRCUIT DIAGRAM


Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation

GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
Oil Pressure Gauge
Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 4270
Component ..........................................................................................................................................
................................................................. Photo No.

................................................................................ 63
................................................................................................................................ 47
.............................................................................................................................. 44
............................................................................................................................... 47

........................................................................................................................ 39

............................................................................................................................................................
22

................................................................................................................................................. 47
.............................................................................................................................. 43
.............................................................................................................................. 43

................................................................................................................................................ 71

............................................................................................................................................... 71

....................................................................................................................................................... 76

...................................................................................................................................................... 76

...................................................................................................................................................... 76
.................................................................................................................................. 70
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Information > Testing and Inspection > Quick Check

Information > Testing and Inspection > Quick Check > Page 4297



Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator >
Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation
GROUP ENGINE
AFFECTED VEHICLES
SERVICE INFORMATION
SERVICE PROCEDURE
Oil Pressure Gauge
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator >
Component Information > Technical Service Bulletins > Engine Oil Pressure Gauge/Lamp - Operation > Page 4304
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Locations

Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information >
Shift Light Circuit
PURPOSE
LOCATION
OPERATION
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 9204005 > May > 92 > Speedometer Cable -
Ticking Noises
Speedometer Cable: All Technical Service Bulletins Speedometer Cable - Ticking Noises
ISSUE DATE May 28, 1992
GROUP ELECTRICAL
RODEO (UC) SPEEDOMETER CABLE NOISY
AFFECTED VEHICLES
SERVICE INFORMATION
Some vehicles may experience a ticking noise coming from the dash area, caused by the
speedometer inner cable rubbing against the outer cable housing. This condition also causes the
speedometer needle to fluctuate.
This condition can be eliminated by lubricating the speedometer cable housing with a special
grease, as described in this Service Bulletin.
SERVICE PROCEDURE
1. Raise the vehicle on a hoist.
2. Remove the speedometer cable assembly from the transmission housing and from the two cable
clips.
3. Lower the vehicle from the hoist.
4. In the engine compartment, remove the speedometer cable assembly from the three clips
securing it to the firewall. Pull the cable assembly up through the chassis.
5. Extend the speedometer cable assembly in a straight line.
6. Remove the inner flexible speedometer cable. Use care to keep the small flat washer on the
transmission end of the cable.
7. Apply a small amount of speedometer cable grease (see "Parts Information" section of this
Service Bulletin) to the transmission end of the speedometer cable housing.
8. Reinstall the flexible cable into the cable housing, rotating it by hand for smoother insertion.
9. Reinstall the speedometer cable assembly as follows:
a. Reroute the cable assembly through the chassis, using care to prevent kinking the cable.
b. Reinstall the cable assembly to the three clips inside the engine compartment.
11. Reinstall the cable assembly to the transmission and the two cable clips.
13. Test drive the vehicle to ensure proper speedometer operation.
PARTS INFORMATION

2-90067-203-0 Speedometer Cable Grease
NOTE
Ticking Noises > Page 4320
Approximately 15 vehicles can be serviced using this container of grease.
Copies of the Material Safety Data Sheet and Environmental Data Sheet for this grease are
included in this Service Bulletin.
When submitting a warranty claim for this labor operation, use part No. N-PNGRE-ASE-1 for
reimbursement of $ 1.00 (includes dealer mark-up) for grease material allowance.
Material Safety Data Sheet
Environmental Data Sheet

Information > Technical Service Bulletins > Customer Interest: > 9204005 > May > 92 > Speedometer Cable - Ticking
Noises
Speedometer Cable: Customer Interest Speedometer Cable - Ticking Noises
GROUP ELECTRICAL
RODEO (UC) SPEEDOMETER CABLE NOISY
AFFECTED VEHICLES
SERVICE INFORMATION
Some vehicles may experience a ticking noise coming from the dash area, caused by the
speedometer inner cable rubbing against the outer cable housing. This condition also causes the
speedometer needle to fluctuate.
This condition can be eliminated by lubricating the speedometer cable housing with a special
grease, as described in this Service Bulletin.
SERVICE PROCEDURE
2. Remove the speedometer cable assembly from the transmission housing and from the two cable
clips.
4. In the engine compartment, remove the speedometer cable assembly from the three clips
securing it to the firewall. Pull the cable assembly up through the chassis.
5. Extend the speedometer cable assembly in a straight line.
6. Remove the inner flexible speedometer cable. Use care to keep the small flat washer on the
transmission end of the cable.
7. Apply a small amount of speedometer cable grease (see "Parts Information" section of this
Service Bulletin) to the transmission end of the speedometer cable housing.
8. Reinstall the flexible cable into the cable housing, rotating it by hand for smoother insertion.
9. Reinstall the speedometer cable assembly as follows:
a. Reroute the cable assembly through the chassis, using care to prevent kinking the cable.
b. Reinstall the cable assembly to the three clips inside the engine compartment.
11. Reinstall the cable assembly to the transmission and the two cable clips.
13. Test drive the vehicle to ensure proper speedometer operation.
PARTS INFORMATION

2-90067-203-0 Speedometer Cable Grease
NOTE
Noises > Page 4332
Approximately 15 vehicles can be serviced using this container of grease.
Copies of the Material Safety Data Sheet and Environmental Data Sheet for this grease are
included in this Service Bulletin.
When submitting a warranty claim for this labor operation, use part No. N-PNGRE-ASE-1 for
reimbursement of $ 1.00 (includes dealer mark-up) for grease material allowance.
Noises > Page 4333
Noises > Page 4334
Noises > Page 4335
Noises > Page 4336
Material Safety Data Sheet
Noises > Page 4337
Noises > Page 4338
Environmental Data Sheet

Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Cable: > 9305014 > Jul > 93 > A/T -
Clunking Noise on 3-2 Downshift
GROUP TRANSMISSION
AFFECTED VEHICLES
SERVICE INFORMATION
condition.
SERVICE PROCEDURE
PARTS INFORMATION
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > Quick Check
Speedometer Head: Testing and Inspection Quick Check
DIAGNOSIS (V6, 3.2L)
QUICK CHART FOR CHECK POINTS
1. Speedometer
Speedometer Head: Testing and Inspection Diagnosis
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures
Tachometer: Symptom Related Diagnostic Procedures
Quick Check
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4360
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Symptom Related Diagnostic Procedures




Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >

Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T >
Isuzu Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component
Information > Testing and Inspection
Volt Meter Gauge: Testing and Inspection
QUICK CHECK
FLOW CHART
Isuzu Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram
Backup Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Backup Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Backup Lamp: Electrical Diagrams
Back Up Lights: Automatic Transmission

Back Up Lights: Manual Transmission
Isuzu Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution
and Instructions > Page 4408

Brake Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Brake Lights
Isuzu Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Locations
Cargo Lamp: Locations
Component ..........................................................................................................................................
................................................................. Photo No.

................................................................................ 63
Diode Box C - Behind left side of I/P, taped to harness

...................................................................................................................................................... 73
Hatch Gate Open Switch - Inside top center of tailgate, on latch assembly
...................................................................................................................... 118
Left Front Door Switch - Rear of left front door area

......................................................................................................................................................... 99
Left Rear Door Switch - Rear of left door area ....................................................................................

............................................................................. 103
Right Front Door Switch - Rear of right front door area

..................................................................................................................................................... 99
Right Rear Door Switch - Rear of right rear door area

...................................................................................................................................................... 103
........................................................................................................................ 89
C226 (2-WHT) - Behind left side of I/P, taped to harness

.................................................................................................................................................. 73
C227 (14-WHT) - Inside left kick panel ................................................................................................

............................................................................. 93
C250 (20-BLK) - Below right side of I/P, at kick panel

..................................................................................................................................................... 92
C252 (8-BLK) - Inside right kick panel .................................................................................................

............................................................................. 93
C303 (1-CLR) - Rear of left front door area, behind door switch
....................................................................................................................................... 99
C304 (8-WHT) - Inside left "B" pillar, near grommet

...................................................................................................................................................... 100
C309 (1-CLR) - Rear of right front door area, behind door switch
..................................................................................................................................... 99
C310 (8-WHT) - Inside right "B" pillar, near grommet

.................................................................................................................................................... 100
C401 (1-CLR) - Rear of left rear door area, behind door switch
...................................................................................................................................... 103
.................................................................................................... 61
....................................................................................................... 61
C409 (1-CLR) - Rear of right rear door area, behind door switch
.................................................................................................................................... 103
C412 (6-BLK) - Right side of luggage room, behind lower trim cover
............................................................................................................................ 115
C502 (2-WHT) - In rear of left front door, behind door courtesy light
............................................................................................................................... 95
C602 (2-WHT) - In rear of right front door, behind door courtesy light
............................................................................................................................. 95
C702 (2-WHT) - Inside rear of left rear door, behind door courtesy light
........................................................................................................................ 101
C802 (2-WHT) - Inside rear of right rear door, behind door courtesy light
...................................................................................................................... 101
C900 (1-CLR) - Center of ceiling, above dome light

........................................................................................................................................................
105

........................................................................................................................................................
105
C902 (1-CLR) - Center front of ceiling, above spot light assembly

.................................................................................................................................. 104
C903 (1-CLR) - Center rear of ceiling, above luggage room light

.................................................................................................................................... 117

.................................................................................................................................... 117
Isuzu Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Cargo Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Cargo Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Cargo Lamp: Electrical Diagrams

Dome, Luggage Room, Courtesy And Spot Lights

Isuzu Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram
Courtesy Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Courtesy Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Courtesy Lamp: Electrical Diagrams


Isuzu Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Dome Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Dome Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Dome Lamp: Electrical Diagrams


Isuzu Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Diagram
Fog/Driving Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Fog/Driving Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Off-Road Lights
Isuzu Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram
Hazard Warning Lamps: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Hazard Warning Lamps: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Turn Signal And Hazard Lights

Isuzu Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
Component ..........................................................................................................................................
................................................................ Photo No.

...................................................................................................................................................... 75

................................................................................ 63

...................................................................................................................... 16

............................................................................................................................. 17
................................................................................................ 62

................................................................................................................................................. 90
........................................................................................................................ 89

.............................................................................................................................................................
1

............................................................................... 4

.............................................................................................................................................................
2

........................................................................................................................................................... 1

................................................................................................................................................ 72

.............................................................................................................................................. 88

...................................................................................................................................................... 66

................................................................................................................................................ 71

............................................................................................................................................... 71

............................................................................................................................ 81

............................................................................ 108
............................................................................ 109

....................................................................................................................................................... 76

...................................................................................................................................................... 76
................................................................................................................................ 84
....................................................................................................................... 84
................................................................................................................................ 84

.............................................................................................................................................................
111

........................................................................... 122
.................................................................................................... 61
....................................................................................................... 61

..............................................................................................................................................................
122

.................................................................................................................................. 62
................................................................................................................................. 70
Isuzu Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Headlight Switch
Headlight Switch
Headlight Switch
Isuzu Workshop Manuals > Lighting and Horns > Horn > Component Information > Locations
Horn: Locations
Component ..........................................................................................................................................
................................................................. Photo No.

...................................................................................................................... 16
High Note Horn - Behind right side of radiator grille

........................................................................................................................................................... 2
Low Note Horn - Behind right side of radiator grille

............................................................................................................................................................
2

.............................................................................................................................................. 88

............................................................................................................................ 81
Isuzu Workshop Manuals > Lighting and Horns > Horn > Component Information > Diagrams > Diagram Information and
Instructions
Horn: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Horn: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Horns
Isuzu Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
License Plate Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

License Plate Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


License Plate Lamp: Electrical Diagrams
Front Side Marker, Front Park, Rear Park And License Plate Lights
Isuzu Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations
Map Light: Locations
Component ..........................................................................................................................................
................................................................. Photo No.

................................................................................ 63
Diode Box C - Behind left side of I/P, taped to harness

...................................................................................................................................................... 73
Hatch Gate Open Switch - Inside top center of tailgate, on latch assembly
...................................................................................................................... 118
Left Front Door Switch - Rear of left front door area

......................................................................................................................................................... 99
Left Rear Door Switch - Rear of left door area ....................................................................................

............................................................................. 103
Right Front Door Switch - Rear of right front door area

..................................................................................................................................................... 99
Right Rear Door Switch - Rear of right rear door area

...................................................................................................................................................... 103
........................................................................................................................ 89
C226 (2-WHT) - Behind left side of I/P, taped to harness

.................................................................................................................................................. 73
C227 (14-WHT) - Inside left kick panel ................................................................................................

............................................................................. 93
C250 (20-BLK) - Below right side of I/P, at kick panel

..................................................................................................................................................... 92
C252 (8-BLK) - Inside right kick panel .................................................................................................

............................................................................. 93
C303 (1-CLR) - Rear of left front door area, behind door switch
....................................................................................................................................... 99
C304 (8-WHT) - Inside left "B" pillar, near grommet

...................................................................................................................................................... 100
C309 (1-CLR) - Rear of right front door area, behind door switch
..................................................................................................................................... 99
C310 (8-WHT) - Inside right "B" pillar, near grommet

.................................................................................................................................................... 100
C401 (1-CLR) - Rear of left rear door area, behind door switch
...................................................................................................................................... 103
.................................................................................................... 61
....................................................................................................... 61
C409 (1-CLR) - Rear of right rear door area, behind door switch
.................................................................................................................................... 103
C412 (6-BLK) - Right side of luggage room, behind lower trim cover
............................................................................................................................ 115
C502 (2-WHT) - In rear of left front door, behind door courtesy light
............................................................................................................................... 95
C602 (2-WHT) - In rear of right front door, behind door courtesy light
............................................................................................................................. 95
C702 (2-WHT) - Inside rear of left rear door, behind door courtesy light
........................................................................................................................ 101
C802 (2-WHT) - Inside rear of right rear door, behind door courtesy light
...................................................................................................................... 101

........................................................................................................................................................
105

........................................................................................................................................................
105
C902 (1-CLR) - Center front of ceiling, above spot light assembly

.................................................................................................................................. 104

.................................................................................................................................... 117

.................................................................................................................................... 117
Isuzu Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information
and Instructions
Map Light: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Map Light: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Map Light: Electrical Diagrams


Isuzu Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram
Marker Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Marker Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Marker Lamp: Electrical Diagrams
Isuzu Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Parking Lamp: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Parking Lamp: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Parking Lamp: Electrical Diagrams
Isuzu Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component ..........................................................................................................................................
................................................................ Photo No.

...................................................................................................................................................... 75

................................................................................ 63

...................................................................................................................... 16

............................................................................................................................. 17
................................................................................................ 62

................................................................................................................................................. 90
........................................................................................................................ 89

.............................................................................................................................................................
1

............................................................................... 4

.............................................................................................................................................................
2

........................................................................................................................................................... 1

................................................................................................................................................ 72

.............................................................................................................................................. 88

...................................................................................................................................................... 66

................................................................................................................................................ 71

............................................................................................................................................... 71

............................................................................................................................ 81

............................................................................ 108
............................................................................ 109

....................................................................................................................................................... 76

...................................................................................................................................................... 76
................................................................................................................................ 84
....................................................................................................................... 84
................................................................................................................................ 84

.............................................................................................................................................................
111

........................................................................... 122
.................................................................................................... 61
....................................................................................................... 61

..............................................................................................................................................................
122

.................................................................................................................................. 62
................................................................................................................................. 70
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Headlight Switch
Headlight Switch
Headlight Switch
Isuzu Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
screws.
Isuzu Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service
and Repair
screws.
Isuzu Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Heated Glass Element: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Heated Glass Element: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Rear Defogger
Isuzu Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams >
Power Window Motor: Diagram Information and Instructions
Circuit Schematics
CIRCUIT APPLICATION
CURRENT FLOW
CIRCUIT NETWORKING
HARNESS ROUTING
CONNECTOR I.D.
Fuse Box Details
energized.
Ground Distribution
to a splice.
Power Distribution

Power Window Motor: Diagnostic Aids
Meter Types
Diode Check
STATIC DISCHARGE
TESTING
CONTROL UNIT DAMAGE
Battery Precautions
CAUTION: -
battery.
PRECAUTIONS
TESTING PROCEDURES
Meter Types
EXAMPLE

the relay)
Voltage Check
Meter Types
Voltage Check
EXAMPLE:
PURPOSE
CIRCUIT BREAKERS

Fig. 1 Fuse Devices

FUSES
Autofuse
Maxifuse
of nuisance blows.
Minifuse

FUSIBLE LINKS
links.
the way through.
insulation.
protection.
SERVICE PROCEDURE
procedure).

Step 5: Solder
moisture scaling.
causing damage.


proper nest.
the splice.

tape.
17.
Pack.

the connector.

WEATHER PACK
connector.
Terminal Repair


Power Window Motor: Electrical Diagrams

Power Windows
Power Windows
Isuzu Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Safety Glass - Identification & Maintenance
Windshield: Technical Service Bulletins Safety Glass - Identification & Maintenance
ISSUE DATE: FEBRUARY 2001
GROUP: BODY
AUTOMOTIVE SAFETY GLASS: IDENTIFICATION AND MAINTENANCE
AFFECTED VEHICLES
All Isuzu Vehicles
SERVICE INFORMATION
Safety glass as the word says it provides some form of protection for occupants in automobiles.
From the introduction of the windshield in the early 1900's, there have been so much importance
placed on the windshield from hue/road debris deflectors to becoming an important part of the
vehicle's safety structure. The early windshields may have provided a more comfortable drive, but
once flying debris strikes the windshield, the windshield is fractured causing dangerous glass
fragments to fly into the cabin and possibly injuring the occupants. Today's windshields has been
engineered with more advanced technology giving it enough strength to prevent occupant(s) in the
vehicle from being thrown out of the windshield and resiliency to reduce injury in case of occupant
impact on to the windshield.
There are two types of commonly used automotive safety glass. They are laminated glass and
tempered glass, which will be covered in this bulletin. Also, covered in this bulletin are valuable
information for safe use and handling of automotive safety glass.
Safety Glass - Identification & Maintenance > Page 4811
Identifying Vehicle Windows
Glass Properties
1. The basic ingredients of glass are silica sand, soda ash, and limestone. More ingredients are
added depending on the glass application. As basic a glass may seem, glass also requires some
maintenance to provide the longevity in its usefulness. Dirt, sand and airborne dust particles may
contain metals and substances that are harder than glass. Glass (i.e.. automobile windshield. etc.)
can be damaged/scratched from dirt, sand and airborne dust particles that may come in contact
with it if not removed. Dirty wiper blades imbedded with dirt; sand and airborne dust particles can
damage the front windshield if used without first rinsing the windshield clear of them.
2. Glass subject to external forces may be damaged from scratches. or break as a result of high
impact on the glass.
Types and Characteristics of Automotive Safety Glass
There are two types of commonly used automotive safety glass. They are laminated glass and
tempered glass.
(1) Laminated Glass*
Laminated glass is a type of glass with a tough plastic film (Poly Vinyl Butyral a.k.a. PVB) is
sandwiched between two sheets of glass bonded together in a vacuum under controlled
temperature and pressure forming a single sheet, to provide a high degree of safety. This is
followed by extensive tests prior to receiving clearance for usage. Laminated glass (used for
automotive windshields) found in practically all automobiles produced, are part of current safety
regulations for production vehicles.
*Properties of Laminated Glass:
^ The interlayer cuts ultraviolet rays.

^ The plastic interlayer adhesion prevents the two glass layers from splitting and shattering into the
cabin (resulting in occupant injuries). This ensures undistracted driver field of vision, thus lessens
possible injuries.
^ The automobile windshield (made of laminated glass) is designed to break but not shatter, will
absorb the impact (lessening bodily injuries) of the human body in the event of an accident
(head-on collision) than tempered glass.
(2) Tempered Glass**
Tempered glass consists of a tensile stress layer sandwiched between two compressive stress
lavers. This three-layer glass is produced by heating a glass plate to its softening point (approx.
700°C) and quenching it with air. Tempered glass is used in automobiles for side door windows,
backlight windows, rear quarter windows. sun-roof/moon-roof glass and other windows except the
front windshield.
**Properties of Tempered Glass
^ The outer layer (compressive stress layer) of the tempered glass resists given external forces
(tensile forces). This layer gives the tempered glass three to five times impact strength than a
normal glass plate of the same thickness.
^ The tempered glass will shatter into small particles (with no sharp edges) if breakage occurs to
reduce possible injuries.
^ Tempered glass can resist sudden temperature changes (thermal shock).
Scenarios of Damaged Front Windshields (Laminated Glass)
Breakage in Laminated Glass
Scenario: A crack is found on the windshield after returning to a parked vehicle.

Cause: A small scratch on the windshield was unnoticed, which developed into a crack. This may
have developed as a stress crack emanating from vehicle load stress concentrating on the
vehicle's weakest point (the windshield).
NOTE:
A flying pebble may have caused the scratch (which mainly occurs from the external surfaces of
the glass.
Why cracks develop? Cracks develop when stress is applied to the impact site. The impact site is
the actual location of the outer glass layer where an object (i.e., flying pebble) struck the
windshield, chipping away a small piece of glass.
Stress is defined as:
^ Vibrations result from wind pressure while the vehicle is moving.
^ Vehicle body stress from turning and moving (i.e., rolling, pitching and yawing).
^ Thermal stress (temperature difference between interior and exterior temperatures of the
vehicle).
Here is an example of a scratch caused by a flying pebble on the windshield.
PREVENTATIVE TIPS FOR WINDSHIELD CARE:
[ ] Select a parking location where the vehicle is not exposed to potential hazards from flying
pebbles or gravel.
[ ] Avoid driving behind trucks at a close distance, especially the ones that haul gravel. (Truck tires
may sometimes-pickup loose gravel/pebble in its tire
grooves and may sling shot to your windshield.)
Scratches on Laminated Glass
Instructions for Proper Handling of Laminated Glass
Laminated glass should be kept away from high heat or heat generating equipment/appliance
during transport and/or storage. The interlayer may bubble or become deformed it left exposed to
high heat.
Scenarios of Damaged Backlight Glass and Door Glass (Tempered Glass)
[ ] The glass broke while the vehicle was being driven.
[ ] The glass broke while parked for a short time.

[ ] The glass broke when the door was closed.
[ ] The glass has scratches on the inner-side that is visible from the outside.
Causes: Several causes may play a factor to tempered glass (i.e., backlight glass or door glass)
damage during vehicle operation or on a parked vehicle.
^ Impact of flying pebble causing a scratch. (See Scenario 1 and 2).
^ Various stress factors from wind pressure and vibrations while operating the vehicle are
continually applied to the "unnoticed" scratch (from the flying pebble) until the scratch reaches the
inner tensile stress layer, will lead to glass breakage. (See Scenario 1 and 2)
Glass Breakage Flow Chart
Scenario 1: Damage reaches the inner tensile stress layer of the tempered glass to cause
breakage.
Scenario 2: At the initial impact, damage remains in the outer compressive stress layer. While
operating the vehicle, various stress factors from wind pressure and vibrations are continually
applied to the scratch (from the flying pebble) until the scratch reaches the inner tensile stress
layer, that leads to glass breakage.
Backlight Glass with Damaged Defroster Lines

This section describes failures that have recently been observed in station wagons and SUVs with
tailgates. These are defective heat generation by the defroster-printed lines.
Cosmetic Defects in Side Door Glass
The vehicle's door glass is one of the most exposed glasses to heavy usage in the vehicle, as well
as susceptibility to damage by the user. Here are some examples to common scenarios.
Other Related Defects
Damage due to mishandling
Maintenance of Soiled and Stained glass

Glass Molding Surface Damage

Windshield: Technical Service Bulletins Windshield Glass - Cleaning Recommendations
GROUP MISCELLANEOUS
WINDSHIELD GLASS CLEANING
AFFECTED VEHICLES
All Isuzu models.
SERVICE INFORMATION
When cleaning the front or rear windshield glass (such as during PDI or during glass installation),
use only glass cleaner or "bug and tar remover" type solvent. Do not use a razor blade or gasoline
to clean the glass surface, as damage to the glass may result.
Isuzu Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Testing and Inspection
4, Fig. 60.
7.

Isuzu Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Testing and Inspection > Intermittent Wiper Relay
Isuzu Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Testing and Inspection > Intermittent Wiper Relay > Page 4831
replace relay.
Isuzu Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Front Wiper Switch

Isuzu Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Front Wiper Switch > Page 4837
Wiper Switch: Testing and Inspection Rear Wiper Switch
Wiper And Washer Switch
Rear Wiper And Washer Switch Inspection
Check for continuity between switch connector terminals.

Isuzu Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Testing and
Inspection
4, Fig. 60.
7.

Isuzu Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection
> Low Speed and High Speed Inspection
Wiper Motor: Testing and Inspection Low Speed and High Speed Inspection
Fig. 56 Front Wiper Motor Connector
1. Remove wiper motor assembly.
2. Position in suitable vise.
3. Inspect wiper motor low speed operation as follows: a. Connect positive battery voltage to
terminal No. 2 and negative to terminal No. 3, Fig. 56. b. Ensure proper motor low speed operation.
4. Check motor high speed operation as follows: a. Connect positive battery voltage to terminal No.
1 and negative to terminal No. 3. b. Ensure proper motor high speed operation.
5. Inspect motor auto stop operation as follows: a. Connect positive battery voltage to terminal No.
6 and negative to terminal No. 3. b. Ensure proper low speed operation, then disconnect positive
battery terminal. Motor should stop. c. Using suitable lead wire, connect terminals No. 2 and 5. d.
Connect positive battery terminal to terminal No. 4. Motor should restart. e. Ensure proper motor
auto-stop operation.
> Low Speed and High Speed Inspection > Page 4845
Wiper Motor: Testing and Inspection Rear Wiper Motor
Wiper Motor Connector
Check that the motor operates when the (+) side battery voltage is connected to the motor terminal
No.4 and (-) side is connected to the terminal No.3.
> Page 4846
Wiper Motor: Service and Repair
1. Ensure wiper blade assemblies are in the park position. 2. Disconnect electrical connector from
wiper motor assembly. 3. Remove wiper motor retaining bolts, then position crank arm flat on
bottom of wiper linkage access hole. 4. Remove wiper motor linkage retaining bolt, then wiper
motor assembly from vehicle. 5. Reverse procedure to install, noting the following:
a. If crank arm of wiper motor was removed, confirm position of auto stop prior to installing crank
arm to wiper motor. b. Torque crank arm retaining nut to 9-11 ft. lbs.
Isuzu Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection
> Intermittent Wiper Relay
Isuzu Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection
> Intermittent Wiper Relay > Page 4851
replace relay.
Isuzu Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Front Wiper Switch

Isuzu Rodeo (4wd) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993) ) PDF

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Isuzu Rodeo (4wd) Workshop Manual (V6-3165cc 3.2L SOHC (6VD1) (1993) ) PDF

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Factory Workshop Manual

Engine and year

V6-3165cc 3.2L SOHC (6VD1) (1993)

Please navigate through the PDF using the options

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For diagnosis of all P codes

POWER AND GROUND SUPPLY

Component/Connector Location and I.D.

COMPONENT AND CONNECTOR LOCATION

Fuse Box Details

Light Switch Details

Wire Color Code Identification

Continuity and Resistance Check

1. Use a digital or analog multimeter with a minimum 10k ohm resistance.

3. Set the ohmmeter to the appropriate range.

Continuity And Resistance Check

CONTROL UNIT DAMAGE

^ Do not try to disassemble the control unit.

^ Never apply battery power to a component unless directed to do so in a test procedure.

Electronic Component Replacement

1. Before servicing electronic components, disconnect the battery ground.

- Don't disconnect the battery when the engine is running.

- When charging a battery, be sure battery cables are disconnected.

Electrical Connections and Circuits

3. Do not use a self powered test lamp to check continuity.

4. Do not create any arcing to check the continuity of a circuit.

testing electronic components.

Proper Tools and Testing Procedures

DIGITAL VOLT/OHM METER

Finding Short Circuits

1. Use a digital or analog multimeter with a minimum 10k ohm resistance.

3. Connect a test lamp in place of the fuse.

4. Establish conditions that turn the test lamp on.

a) Ignition SW ON b) Ignition SW ON and SW 1 ON c) Ignition SW, SW 1 and Relay ON (connect

1. Use a digital or analog multimeter with a minimum 10k ohm resistance.

2. Establish conditions in which voltage should be present at the check point.

Circuit Protection Devices

CIRCUIT PROTECTION DEVICES

Cycling Circuit Breaker

Non-Cycling Circuit Breaker

Fig. 1 Fuse Devices

Pacific Fuse Element

Fig. 3 Good and Damaged Fusible Links

Determining characteristics of the types of fusible links:

Fig. 5 Double Wire Feed Fusible Link

Typical Electrical Repair

SHORT CIRCUITS CAUSED BY DAMAGED WIRE INSULATION

- Locate the damaged wire.

- Find and correct the cause of the wire insulation damage.

Splicing Copper Wire Using Splice Clips

Step 1: Open the Harness

Fig. 6 Wire Size Conversion Table

Step 3: Strip the Insulation

Fig. 8 Crimping the Splice Clip

Step 4: Crimp the Wires

^ Before crimping the ends of the clip, be sure that: -

The wires extend beyond the clip in each direction.

- No strands of wire are cut loose, and

Fig. 12 Proper Second Taping

Step 6: Tape the Splice

Splicing Copper Wire Using Crimp and Seal Splice Sleeves

Step 1: Open the Harness

Step 2: Cut the Wire