Sections A Thru I

Section A: STEERING YOKE SPRING INSTALLATION (1998 - 2000 Models)

NOTE:
Proceed to Step 9 in Section B for 2001 models.

2. Turn the steering wheel to the center position.

3. Lift the vehicle on the hoist.

4. At the bottom of the steering rack, locate the yoke plug and clean the plug and the surrounding surface.





5. Partially loosen the lock nut (42 mm) to loosen and remove the threaded yoke plug. (Figure 1)

^ This will allow access and removal of the yoke spring.

6. Clean the thread face of yoke plug. apply thread sealant and reinstall with new (Light Gray) spring.





7. Turn yoke plug fully clockwise to bottom-out the plug. Mark and index the position of the yoke plug in relation to the housing, then turn yoke plug counter-clockwise 30° +/- 3° (approximately 12 mm from index mark on housing)

IMPORTANT:
If Yoke Plug set is not adjusted properly, it may cause abnormal wheel returnability characteristic

8. Tighten the lock nut to the specified torque of 50 lb. Ft (68 N.m). while keeping the original location of the yoke plug.

Section B: STEERING JOINT INSPECTION AND ALIGNMENT

9. Set vehicle down on level ground.








10. Inspect the alignment of the rubber coupling at the 2 steering shaft. (Figures 3 and 4)

11. If the steering rubber coupling is mis-aligned, continue to Step 12. Continue to Step 15 if the rubber coupling is properly aligned. (Figure 3)





12. Loosen the pinch bolt of the steering shaft, which is under the hood and below the brake master cylinder. (Figure 5)





13. Using a pry bar, adjust the coupling area to align the rubber coupling through the service cutout in the left-front wheel housing. (Figure 6)

14. Retighten the steering shaft pinch bolt to the specified Torque of 23 lb. ft (31 N.m).

Section C: INSTALLATION of # 1 BODY
MOUNT-SHIM
BODY MOUNT CLEARANCE INSPECTION & CORRECTION

15. While the vehicle is still on level ground, inspect and measure the upper clearance gap of the No. 1 body mount located behind the front bumper.








^ There should be a minimum of 2 mm clearance gap between the mounting rubber at the upper half of both the left and right No. 1 body mounts. (Figures 7 and 8)

16. If the clearance is less than 2 mm, then continue to Step 17. If the clearance is at least 2 mm, then proceed to Step 33.





17. Remove the front plastic door sill plate and kick panel, and lift the carpet to remove the No. 2 body mount bolt access plug. (Figure 9)





18. Remove the rear plastic door sill plate, and lift the carpet to remove the No. 3 body mount bolt access plug. (Figure 10)





19. Loosen and remove the No. 2 body mount bolt and the washer/nut through the access hole underneath the mount. (Figure 11)





20. Loosen and remove the No. 3 body mount bolt and the washer/nut through the access hole underneath the mount. (Figure 12)





21. Loosen the No. 1 body mount bolt and nut. Do not remove the bolt from this mount. (Figure 13)

22. Partially lift the body under the body flange rail at the mid-point of the front door (away from the frame) using a floor-jack and the body lifting adapter tool (J-44267).





IMPORTANT:
Carefully lift the body up to the amount required for shim installation only. Excessive lifting height with the floor jack may damage the body or other components. (Figure 14)





23. Add 2 shims to the top of the No. 2 body mount hushing (between the body and mount). Reinstall the body mount bolt through the access hole, and hand-thread the bottom nut. (Figure 15)





24. Add 1 shim to the top of the No. 3 body mount bushing between the body and mount). Reinstall the body mount bolt through the access hole, and hand-thread the bottom nut. (Figure 16)

25. Carefully lower the floor-jack.





26. Tighten the No. 2 body mount bolt and nut to the specified Torque of 37 lb. ft (50 N.m). (Figure 17)

IMPORTANT:
Apply torque values by hand with an appropriate torque wrench. Do not use air tools when applying torque values for this section.





27. Tighten the No. 3 body mount bolt and nut to the specified Torque of 37 lb. Ft (50 N.m). (Figure 18)





28. Tighten the No. 1 body mount bolt and nut to the specified Torque of 37 lb. Ft (50 N.m). (Figure 19)

29. Repeat Steps 17 through 28 for the other side.

30. Remove any body undercoating residue from your hands prior to the reinstallation of the interior parts.

CAUTION:
Undercoating residue is difficult to remove if the vehicle interior is stained. Wash hands thoroughly prior to handling the interior components.

31. Reinstall the following interior parts for both sides:

^ All removed access plugs (4)

^ Interior carpet (fit into place)

^ Front and rear door sill plates

^ Front kick panels

32. Verify the repair by re-measuring the upper clearance gap of the No. 1 body mount. There should be a minimum of 2 mm clearance gap between the mounting rubber at the upper half of both the left and right side No. 1 body mounts.

Section D: RIDE HEIGHT ADJUSTMENT

33. The following items are needed in this procedure (which can be acquired at your local hardware store):

^ A 15-centimeter steel pocket ruler.

^ Kite string. About three feet in length.

^ Line level

^ "Crossmark" on a nut with magnet

NOTE:
If the above items are not available, use the procedure for ride height adjustment in the appropriate workshop manual.





34. Glue the magnet to the outside of the crosshair nut (P/N 8-97141-154-0). (Figure 20)

35. Paint a "crossmark" on the center of the nut/magnet for reference. (Figure 20)

36. Place the vehicle on level ground or the Alignment Rack.

37. Make certain the vehicle has the correct tire pressure according to the vehicle's specified tire pressure located on the driver side B-pillar or the owner's manual





38. Install the "crossmarked" nut onto the Lower Control Arm Bolt spinning the bolt on at least three turns. (Figure 21)

39. Align the "crossmark" in a perfect horizontal position.





40. Place the steel ruler on the crosshair mark. (Figure 22)

41. Tie the string to the lower ball joint nut and pull the string to the ruler until the bubble is centered in the sting level. (Figure 22)

42. Once the Line Level is centered, take your reading on the ruler. The correct vehicle specification for the Rodeo is 119 +/- 5 mm.





43. Make the necessary adjustments with the adjusting bolt on the height control arms.

Section E: A/C BRACKET MOUNTING TORQUE





44. Inspect the A/C bracket bolts for torque specifications. The correct torque should be 14 lb ft (19 N.m).

45. Proceed to Step 46 for 1998 - 2000 2WD Vehicles. Proceed to Step 50 for 2001 and 4WD Vehicles.

Section F: REAR HUB CENTERING RINGS

This section pertains only to 1998 - 1999 and 2000 RODEO 2 Wheel Drive vehicles built prior to VIN breakpoint:
2Y4329627. If you are working on a 4Wheel Drive vehicle that still exhibits body vibration, go to Step 50 in Section G "Tire Balancing Procedures."

46. Lift the vehicle and remove the rear wheels.





47. Clean any dirt build-up on the axle hub area. Install the rear wheel centering ring by sliding it onto the axle hub. (Figure 25)





48. Clean the frame thoroughly, remove any dirt or grease and install the Centering Ring Information Label to the frame. (Figure 26)

49. Repeat steps 47 through 48 for the other side.

Section G: TIRE BALANCING PROCEDURE TIRE/WHEEL VIBRATION DIAGNOSIS USING A 2 DIMENSIONAL DYNAMIC BALANCER

IMPORTANT:
Dynamic tire balancing is required for this operation.

50. With the vehicle on the hoist, remove all four wheels.

51. Inflate the tires to 50 psi to seat the bead.

52. Lower the tire pressure according to the vehicle's specified tire pressure located on the driver side B-pillar or the owner's manual.








53. Perform a dynamic tire balance on all 4 wheels using the Kent Moore 2 Dimensional Balancer or equivalent with the Haweka Wheel Balancer Adapter (Select the appropriate adapter for your wheel balancer equipment in the table listed). Make sure that the tire imbalance does not exceed .25 ounces on either side of the tire. (Figure 27)

54. Reinstall the wheel and tighten the lug nuts to the specified Torque of 87 lb. ft (118 N.m).





55. Lower the vehicle from the hoist and road test the vehicle to determine if the vibration has been eliminated. If the vibration has been eliminated, then return the vehicle to the customer. If the vibration still exists proceed to Step 56 in Section H, "TIRE REPLACEMENT."

Section H: TIRE REPLACEMENT

IMPORTANT:
The repair procedures mentioned in Sections A through Section G must be performed prior to performing Section H.





56. If the procedures outlined above have not been successful in resolving the vibration, fill out the Tire & Request Form and fax the Tire Request Form (Fax Number (562) 926-0415) to the Isuzu Tire Desk.

NOTE:
Incomplete forms will be rejected and may cause delay in your order. For additional information, please contact the "Isuzu Tire Desk" (1-866-854-8341).

Section I: TIRE INSTALLATION

57. The new tires should be mounted and balanced for the customer (for Tire Only replacements).








IMPORTANT:
For Yokohama tires with 15" Steel Wheel mounting, align the yellow dot on the tire with the punch mark on the wheel. The punch mark is located approximately 180° from the wheel production stamp. (Figure 28)

58. Install the Tire and Wheel Assembly (for both Tire Only replacements, and Tire and Wheel Assembly replacements).