Isuzu Trooper 1998 3.5L Workshop Manual

isuzu :: Isuzu Truck Trooper S V6-3.5L (1998)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Antitheft and Keyless Entry Control Unit

Alarm Module: LocationsAntitheft and Keyless Entry Control Unit

Behind Front Console

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Antitheft and Keyless Entry Control Unit > Page 8

Alarm Module: LocationsAlarm and Relay Control Unit

116 - Behind Right Side Of Dash

Behind Right Side Of Dash

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations

Keyless Entry Module: Locations

Behind Front Console

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Locations

Relay Module: Locations

116 - Behind Right Side Of Dash

Behind Right Side Of Dash

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations

Keyless Entry Module: Locations

Behind Front Console

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations

Sunroof / Moonroof Module: Locations

Rear Of Roof

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations

Electronic Brake Control Module: Locations

Right Side Of Engine Compartment

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 26

Electronic Brake Control Module (EBCM)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 27

Electronic Brake Control Module: Description and Operation

ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU)

The EHCU consists of ABS control circuits, fault detector, and a fail-safe. It drives the hydraulic unit according to the signal from each sensor,cancelling ABS to return to normal braking when a malfunction has occurred in the ABS.
The EHCU has a self-diagnosing function which can indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment front right side. It consists of a Motor, Plunger Pump, Solenoid Valves and Check Valve.
On the outside, the relay box containing a motor relay and a valve relay is installed.

Solenoid Valves: Reduces or holds the caliper fluid pressure for each front disc brake or both rear disc brakes according to the signal sent from theEHCU.

Reservoir: Temporarily holds the brake fluid that returns from the front and rear disc brake caliper so that pressure of front disc brake caliper canbe reduced smoothly.
Plunger Pump: Feeds the brake fluid held in the reservoir to the master cylinder.
Motor: Drives the pump according to the signal from EHCU. Check Valve: Controls the brake fluid flow.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 28

Electronic Brake Control Module: Service and Repair

REMOVAL

(EHCU)

1. Remove battery assembly.2. Remove harness connector.3. Remove Electronic Hydraulic Control Unit fixing nuts.4. Remove brake pipes.
^ After disconnecting brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter.

5. Remove hydraulic unit fixing nuts.

INSTALLATION

To install, follow the removal steps in the reverse order, noting the following points:

Torque

^ After installing the hydraulic unit, bleed brakes completely.

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations

Cruise Control Module: Locations

Behind Right Kick Panel

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 33

Cruise Control Module: Service and Repair
Removal

1. Disconnect the battery ground cable.

2. Remove the dash side trim panel (RH)(2).3. Disconnect the connector.4. Remove a fixing nut to remove the cruise control unit (1).

Installation

To install, follow the removal steps in the reverse order.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 41

Compressor Clutch Relay: Testing and Inspection

1. Disconnect relays and check for continuity and resistance between relay terminals.

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations

> Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Locations

> Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Testing and Inspection > Heater and A/C Relay

System Relay: Testing and InspectionHeater and A/C Relay

1. Disconnect heater & A/C relay (B-36).

- When removing the connector for relay, unfasten the tang lock of the connector by using a screwdriver, then pull the relay (1) out.

2. Check for continuity between heater & A/C relay (B-36) terminals.

> Relays and Modules > Relays and Modules - HVAC > System Relay, HVAC > Component Information > Testing and Inspection > Heater and A/C Relay > Page 50

System Relay: Testing and InspectionHeater, A/C, Thermostat and Compressor Relay

1. Disconnect relays and check for continuity and resistance between relay terminals.

> Relays and Modules > Relays and Modules - Instrument Panel > A/T Shift Indicator Module > Component Information > Locations

A/T Shift Indicator Module: Locations

Behind Lower Left Dash Panel

> Relays and Modules > Relays and Modules - Lighting and Horns > Cornering Lamp Relay > Component Information > Locations

Cornering Lamp Relay: Locations

Fuse/Relay Box (Cover Removed)

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations

Fog/Driving Lamp Relay: Locations

Photo 35 - A/C Compressor Relay

Fuse/Relay Box (Cover Removed)

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations

Headlamp Relay: Locations

Fuse/Relay Box (cover Removed)

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations

Horn Relay: Locations

Fuse/Relay Box (Cover Removed)

> Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations

Tail Lamp Relay: Locations

Fuse/Relay Box (Cover Removed)

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations

Relay Box: Component Locations

Fuse/Relay Box

Right Side Of Engine Compartment

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 76

Trooper S V6-3.5L (1998)

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 77

Trooper S V6-3.5L (1998)

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 78

Trooper S V6-3.5L (1998)

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 79

Relay Box: Connector Locations

Relay Location

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Component Locations > Page 80

Trooper S V6-3.5L (1998)

Relay List

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay & Fuse Box

Relay Box: Application and IDRelay & Fuse Box

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay & Fuse Box > Page 83

Trooper S V6-3.5L (1998)

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay & Fuse Box > Page 84

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Relay & Fuse Box > Page 85

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 86

Relay Box: Description and Operation

Battery and load location may require that a switch be placed some distance from either component. This means a longer wire and a higher voltage drop(1). The installation of a relay between the battery and the load reduces the voltage drop (2).Because the switch controls the relay, amperage through the switch can be reduced.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine

Controls - ECM Reprogramming Recommendations

Engine Control Module: Technical Service BulletinsEngine Controls - ECM Reprogramming Recommendations

Information IB03-14-S002
Reprogramming of Powertrain Control Modules (PCM)
ISSUE DATE: FEBRUARY 2003

Affected VehiclesAll Isuzu Vehicles.
Service Information

American Isuzu Motors Inc. continually strives to provide the most technically advanced vehicles possible to meet the ever-increasing demands of theSUV market place. One such area of constant change is the calibrations used within the vehicles Powertrain Control Module (PCM). These changes aremade as a part of on going product improvements and may take place at anytime including during mid-year production.
WHEN SHOULD A PCM CALIBRATION BE UPDATED?

Emission Related - Anytime Isuzu determines that a vehicle's calibration may cause emissions non-conformity, Isuzu will release a campaign bulletin.Vehicle owners and dealership personnel will be notified of the campaign. If re-programming is required, all vehicles listed as affected in the campaignbulletin should have the PCM programmed with the updated calibration.

Symptom Related - Some vehicles operated under certain conditions may exhibit symptoms that lead to a customer concern. Information relating tosymptoms that may be affected by an updated calibration can be found in the comment section of the calibration selection tables. Vehicles should bediagnosed using the symptom description diagnostic tables first, repaired and verified. If (after repairs are completed and verified) the customer'ssymptom closely match a symptom listed in the comment section of a calibration table for the vehicle, the PCM should be programmed with the updatedcalibration. All diagnostics, symptoms, Diagnostic Trouble Codes, and broadcast codes must be documented on the dealership repair order.
(Reference Section 14 Service Policy and Procedure manual)

Diagnostic Trouble Code (DTC) Related - Some vehicles operated under certain conditions may illuminate the Malfunction Indicator Light (MIL).Information relating to DTC's that may be affected by an updated calibration can be found in the comment section of the calibration selection tables.Vehicles should be diagnosed using the DTC diagnostic tables first, repaired and verified. If (after repairs are completed and verified) the customersDTC match a DTC listed in the comment section of a calibration table for the vehicle, the PCM should be programmed with the updated calibration. Alldiagnostics, symptoms, Diagnostic Trouble Codes and broadcast codes must be documented on the dealership repair order. (Reference Section 14Service Policy and Procedure manual)

WHEN SHOULD A PCM CALIBRATION NOT BE UPDATED?

No Problem Found (NPF) - Unless specifically directed by an Isuzu Service Bulletin, a PCM should not be programmed with an updated calibrationbefore repairs have been diagnosed, repaired and verified.

Vehicle is found not to have the latest calibration available - Do not reprogram a PCM with an updated calibration under warranty solely because a laterversion is available. Do not assume all vehicle operators will benefit from changes made in later calibration releases. Beginning with the 2000 modelyear lsuzu PCM's have an adaptive learning function. During the "learning" cycle, engine performance and transmission shift characteristics will bealtered that could lead to customer complaints. Programming a PCM with an updated calibration is warrantable only as a result of a failure as listedabove. Isuzu does not warrant that vehicles will be provided product improvements made after manufacture.

Technical Service Bulletin (TSB) - Anytime when performing the operations listed in a TSB and you are directed to program with an updatedcalibration.

Disclaimer

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Controls - ECM Reprogramming Recommendations > Page 93

Engine Control Module: Technical Service BulletinsPCM - Alternate Reprogramming Procedure

BULLETIN NUMBER:IB01-14-S001

ISSUE DATE:JANUARY 2001

GROUP:MISCELLANEOUS
USING ISUZU POWERLINK DIAGNOSTICS AS AN ALTERNATIVE METHOD TO REPROGRAM THE PCM
AFFECTED VEHICLES
1998 current Trooper, Rodeo, and Amigo/Rodeo Sport
SERVICE INFORMATION

The instructions described in this bulletin is an alternative method in reprogramming the PCM using the Isuzu PowerLink Diagnostics for all 1998 -current Trooper, Rodeo, and Amigo/Rodeo Sport.
Instructions for reprogramming the PCM using PowerLink

1. Install CD # 19. The installation instructions are the same as the previous versions.

2. Click on the ITCS icon on the desktop (Figure 1).

3. Insert the PowerLink Version 2 CD or later for the appropriate model.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Technical Service Bulletins > Engine Controls - ECM Reprogramming Recommendations > Page 94

Trooper S V6-3.5L (1998)

4. Click on the Isuzu PowerLink Diagnostics button (Figure 1).

5. Diagnose any Current DTCs and History DTCs (if any).

:IMPORTANT

Any Current DTCs and History DTCs must first be diagnosed prior to PCM reprogramming.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Technical Service Bulletins > Engine Controls - ECM Reprogramming Recommendations > Page 95

Trooper S V6-3.5L (1998)

6. If no codes are stored and an updated calibration is available, then click the Calibrate button.

7. Click on your calibration selection.

:NOTE

Current release calibrations for 2000 - 2001 Trooper, Rodeo, and Amigo/Rodeo Sport with 3.2L/3.5L engines correct cold start rough idle condition.

8. Click the Program button to begin the reprogramming event.

:IMPORTANT

Verify that the calibration selected is correct before selecting the Program button.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Technical Service Bulletins > Engine Controls - ECM Reprogramming Recommendations > Page 96

Trooper S V6-3.5L (1998)

9. The status bar indicates that the PCM is uploading the new calibration.

10. Vehicle calibration is complete.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine

Controls - ECM Reprogramming Recommendations > Page 97

Engine Control Module: Technical Service BulletinsPCM - Available Programming for Aftermarket Purchases

BULLETIN NUMBER:SB97-03-L004

ISSUE DATE:DECEMBER 1997

GROUP:EMISSIONS
PROGRAMMING OF OVER-THE-COUNTER-PURCHASED REPLACEMENT PCMS

AFFECTED VEHICLES
The following Isuzu LV models and model years:
^ 1996-98 Trooper (UX)

^ 1998 Rodeo (UE)
^ 1996-97 Rodeo (UC)
^ 1996-98 Hombre (TH)
^ 1998 Amigo (UA)

SERVICE INFORMATION

On August 1, 1995, the Environmental Protection Agency (EPA) issued a Federal regulation requiring all vehicle manufacturers to make programmingof powertrain control modules (PCMs) available to the independent aftermarket at a reasonable cost and in a timely manner. This issuance was inresponse to concerns from consumers and the after market industry regarding the inability to purchase a programmed new or remanufactured PCM incases where a non-warranty or physical dunnage repair is involved.

Replacement PCMs come from the manufacturer requiring programming. If a replacement PCM is installed in an affected vehicle without first beingprogrammed, the vehicle will not operate or it may fail to comply with Federal and State emissions requirements.

According to this Federal regulation, programming of replacement PCMs sold over the counter must be made available to the public by no later thanDecember 1, 1997. Isuzu dealers are therefore now responsible for providing customers who purchase a replacement PCM over the counter with themeans to have their replacement PCM programmed. All over-the-counter-purchased replacement PCMs will be programmed at the designatedprogramming center - Par-Tech, Inc.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Technical Service Bulletins > Engine Controls - ECM Reprogramming Recommendations > Page 98

Trooper S V6-3.5L (1998)

Included in this Service Bulletin is a Replacement PCM Programming Form. This form begins the replacement PCM programming process. When acustomer makes an over-the-counter purchase of a replacement PCM, you must provide that customer a photocopy of this form. The form instructs thecustomer to fill in specific vehicle information, along with a return address; then, to ship the replacement PCM and completed form, together with acheck or money order of $55.00 payable to Par-Tech, Inc., to the Par-Tech address printed on the form. Upon receipt at Par-Tech, the replacement PCMwill be calibrated using the most current manufacturer specification, and then priority shipped to the return address entered on the form.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine

Controls - ECM Reprogramming Recommendations > Page 99

Engine Control Module: Technical Service BulletinsPCM - Reprogramming

BULLETIN NUMBER:IBOO-S002

ISSUE DATE:JANUARY 2000

GROUP:INFORMATION
PCM REPROGRAMMING
AFFECTED VEHICLES
All Isuzu built units with reprogrammable PCM.

It is strongly recommended NOT to reinstall the same software or calibration files when reprogramming a Powertrain Control Module. There is notechnical reason that the download files inside the PCM would ever become corrupted after the control module had previously been successfullyprogrammed. With the 2.2L and 4.3L Hombre, a P0601 (Control Module Read Only Memory) Diagnostic Trouble Code could set in memory and theMIL could illuminate if the controller memory became corrupted.

After a necessary reprogramming, it is feasible that certain learned values such as fuel trim, IAC learned positions, certain OBD II diagnostic thresholds,and automatic transmission shift adapts for the engine or transmission might revert back to their original unlearned starting points. As a result, the engineand transmission may temporarily operate differently until the values are re-learned.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations

Engine Control Module: Component Locations

Behind Front Console

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page

102

Engine Control Module: Connector Locations

Behind Front Console

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and

Instructions

Engine Control Module: Diagram Information and Instructions

Symbols

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 105

Trooper S V6-3.5L (1998)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 106

Trooper S V6-3.5L (1998)

Connector

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 107

Trooper S V6-3.5L (1998)

^ The connector pin shape (2) determines whether the connector is male (3) or female (1).

^ The symbol illustrated in the figure is used as connector, in the circuit.

^ Connector is identified with a connector number (6)

^ The applicable terminal number (7) is shown for each connector.