Service Procedure
REPLACING THE 60 AMP ALTERNATOR (Figure 1)
1. Record any radio station presets; then, disconnect the battery ground cable.
2. Using a wrench, pull down on the drive belt tensioner (turn it clockwise) to release the tension; remove the drive belt from the alternator pulley; then, release the drive belt tensioner (turn it counterclockwise) to restore the tension.
3. Remove the two alternator retaining bolts.
4. Disconnect the wire from terminal "B" of the alternator and the wiring harness connector from terminal "C".
5. Remove and discard the existing 60 amp alternator.
6. Place the new 70 amp alternator (Part No. 8-97130-776-1) into position and reconnect the wiring harness connector to terminal "C" and the wire to terminal "B".
7. Reinstall the two alternator retaining bolts. Tighten the bolts as follows:
M10 bolt: 30 lb. ft. (41 Nm)
M8 bolt: 15 lb. ft. (21 Nm)
8. Using a wrench, pull down on the drive belt tensioner (turn it clockwise) to release the tension; slip the drive belt onto the alternator pulley; then, release the drive belt tensioner (turn it counterclockwise) to restore the tension.
9. When installation is complete, go to INSTALLING THE SUPPLEMENTAL GENERATOR CAMPAIGN KIT (PART NO. 2-90000-810-0).
INSTALLING THE SUPPLEMENTAL GENERATOR CAMPAIGN KIT (PART NO. 2-90000-810-0)
1. Disconnect the two grey 3-pin connectors of the engine & battery harness located near the battery.
2. Connect each end of the pigtail harness, supplied from the Supplemental Generator Campaign Kit (Part No.2-90000-810-0), to the appropriate grey 3-pin connector of the engine & battery harness (figure 2).
3. Remove the driver's side instrument panel lower cover assembly and meter cluster assembly in accordance with section 8F of the 1998 Rodeo (UE) Workshop Manual (UE098-WSM-L01). Disconnect the green 5-pin female connector of the instrument harness from the existing rear defogger switch. Remove the existing rear defogger switch from the meter cluster assembly and discard the switch.
4. Remove the rear console assembly and disconnect the POWER and WINTER MODE switch connectors. Remove the lower cluster assembly and transfer knob. Remove the front console assembly. Refer to the Workshop Manual for details.
5. Connect the grey 5-pin male connector of the rear defogger extension harness, supplied from the kit, into the green 5-pin female connector of the instrument harness (figure 3).
6. Route the loose end of the rear defogger extension harness down through the instrument panel assembly, along side the radio assembly, and out through the opening for the lower cluster assembly (figure 4).
7. Remove the black tape from the terminal of the yellow/green wire of the rear defogger extension harness.
8. Disconnect the blue 32-pin connector from the back of the PCM and remove its grey retaining lock (figure 5). Insert the terminal of the yellow/green wire of the rear defogger extension harness into the vacant connector terminal F9 of the blue 32-pin connector (figure 6). Reinstall the gray retaining lock.
9. Disconnect the white 32-pin connector from the back of the PCM and remove its grey retaining lock (figure 7). Locate the red/white stripe wire connected to terminal C12 of the white 32-pin connector.
10. Set the red/white stripe wire of the white 32-pin connector into the trough of the red plastic joint connector, supplied from the kit. Set the red/white stripe wire of the rear defogger extension harness into the remaining trough of the joint connector (figure 8).
IMPORTANT!
The joint connector used in this repair has specific troughs for the main wire and for the spliced wire. The main wire fits into the trough in which its corresponding fold up side has a trough running across its entire length. The spliced wire fits into the trough in which its corresponding fold up side has a molded stop on one end of the trough. To ensure a proper splice, be sure the wires are placed in their correct troughs in the joint connector.
11. While holding the two wires in place, carefully fold up the two sides of joint connector to encase both wires (figure 9). Secure the wires in the joint connector by pinching the joint connector shut using a pair of pliers (figure 10).
12. Reconnect the blue and white 32-pin connectors to the back of the PCM.
13. Reinstall the front console assembly and the rear console assembly. Reinstall the lower cluster assembly and the transfer knob. Refer to the Workshop Manual for details.
14. Install the new rear defogger switch, supplied from the kit, into the opening in the meter cluster assembly. Connect the grey 5-pin female connector of the rear defogger extension harness into the green 5-pin male connector on the back of the new rear defogger switch (figure 11).
15. Reinstall the meter cluster assembly and the driver's side instrument panel lower cover assembly in accordance with section 8F of the Workshop Manual.
16. Reconnect the battery ground cable and reset any radio station presets.
When all repairs have been completed, hook up a scan tool and reprogram the PCM using Isuzu Technical Communication System (ITCS) CD # 10, issued 2/98. When reprogramming is completed, start the engine and check the rear defoggers and mirror defoggers for proper operation. Verify the ignition voltage is within specification. When checks are completed, go to APPLYING THE CAMPAIGN LABEL.