check oil ISUZU TROOPER 1998 Service Repair Manual

GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the
front or rear wheels before lifting the vehicle.
2. Use covers on the vehicle body, seats, and
floor to prevent damage and/or
contaminations.
3. Disconnect the grounding cable from the
battery before performing service operations.
This will prevent cable damage or burning due
to shortcircuiting.
4. Raise the vehicle with a jack set against the
recommended lifting points (see ÒLifting
instructionsÓ in this section).
5. Support the vehicle on chassis stands.
6. Handle brake fluid and antifreeze solution with
great care.
Spilling these liquids on painted surfaces will
damage the paint.
7. The use of the proper tool(s) and special tool(s)
where specified is essential to efficient,
reliable, and safe service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gasket, plastic clips,
O-rings, oil seals, lock washers, and self-
locking nuts at disassembly.
Normal function of these parts cannot be
guaranteed if they are reused.
10. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct
reassembly.11. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and
design according to installation positions.
12. Clean all parts before inspection or
reassembly.
13. Clean the oil ports and other openings with
compressed air to make certain that they are
free of dirt and obstructions.
14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before
installation.
15. Use the recommended liquid gasket to prevent
leakage.
16. Carefully observe all nut and bolt torque
specifications.
17. When service operation is completed, make a
final check to be sure service has been done
properly and problem has been corrected.
18. When removing or replacing parts that require
refrigerant to be discharged from the air
conditioning system, be sure to use the
following tools to recover and recycle the
Refrigerant-134a (R-134a).
For 134a:
Use the R-134a Refrigerant Recovery/Recovery/
Recycling/Recharging/System (ACR
4) or its
equivalent to prevent the discharge of
refrigerant into the air.
0AÐ2 GENERAL INFORMATION

0BÐ2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
3
610
6
1215
9
1820
12
2425
15
3030
18
3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
GASOLINE ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
* Timing belt
Spark plugs (For leaded fuel use)
Spark plugs (For unleaded fuel use)
Exhaust system
Radiator coolant concentration
Cooling system for water leakage
All hoses and pipes in engine compartment
for clog or damage
Fuel filter
Fuel leakage
Fuel tank
* Air cleaner element
Pre air cleaner
Engine drive belt
Valve clearance
O
2 Sensor (For leaded fuel use)
O
2 Sensor (For unleaded fuel use)-
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(Replace every 165,000 km or 100,000 miles)
(Replace every 165,000 km or 100,000 miles)
(Check and adjust if necessary every 100,000 km or 60,000 miles)
(Replace every 150,000 km or 90,000 miles)
CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid leakage
*
(1)Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
*
Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)
FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
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ATATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
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(1): Adjust or change automatic transmission fluid.
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”.

SERVICE INFORMATION 00 Ð 23
AIR CONDITIONING CYCLE TROUBLESHOOTING
No cooling or insuffi-
cient cooling
Insufficient velocity
of cooling air1. Magnetic clutch does not run
2. Compressor is not rotating properly
·Drive belt loosened or broken
·Magnetic clutch face is not
clean and slips
·Incorrect clearance between
magnetic drive plate and pulley
·Compressor oil leaks from shaft
seal or shell
·Compressor seized
3. Insufficient or excessive charge of
refrigerant
4. Leaks in the refrigerant system
5. Condenser clogged or insufficient
radiation
6. Temperature control link unit of the
heater unit defective
7. Unsteady operation due to foreign
substance in expansion valve
8. Poor operation of electronic thermo-
stat
1. Evaporator clogged or frosted
2. Air leaking from cooling unit or air
duct
3. Blower motor does not rotate prop-
erly·Refer to ÒMAGNETIC CLUTCHÓ
troubleshooting
·Adjust the drive belt to the specified
tension or replace the drive belt
·Clean the magnetic clutch face or
replace
·Adjust the clearance (Refer to
Section 1D ÒCOMPRESSOR OVER-
HAULÓ
·Replace the compressor
·Replace the compressor
·Discharge and recover refrigerant.
Recharge to specified amount.
·Check refrigerant system for leaks
and repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
·Clean the condenser or replace as
necessary
·Check radiator or condenser fan
function
·Repair the link unit
·Replace the expansion valve
·Check electronic thermostat and
replace as necessary
·Check evaporator core and replace
or clean the core
·Check evaporator and duct connec-
tion, then repair as necessary
·Refer to Section 00 for ÒFAN
CONTROL KNOB (FAN SWITCH)Ó
troubleshooting
* For the execution of the charging and discharging operation in the table above, refer to the ÒRECOVERY,
RECYCLING, EVACUATING AND CHARGINGÓ in section 1B.
TROUBLEPOSSIBLE CAUSECORRECTION

AIR CONDITIONING 1B Ð 13
ACR41) Using the ACR4(HFC-134a Refrigerant Recovery/
Recycling/ Recharging/ System) or equivalent to
thoroughly discharge and recover the refrigerant.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
2) Remove and replace the defective part.
3) After evacuation, charge the air conditioning
system and check for leaks.
PRECAUTIONS FOR REPLACEMENT OR REPAIR OF
AIR CONDITIONING PARTS
There are certain procedure, practices and precautions
that should be followed when servicing air conditioning
systems:
·Keep your work area clean.
·Always wear safety goggle and protective gloves
when working on refrigerant systems.
·Beware of the danger of carbon monoxide fumes
caused by running the engine.
·Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
·Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
·When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
·Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or
parts are reconnected or installed.
·When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
·Always install new O-rings whenever a connection is
disassembled.
·Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
·When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
ON-VEHICLE SERVICE

AIR CONDITIONING 1B Ð 15
COMPRESSOR LEAKS
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
RECOVERY, RECYCLING, EVACUATION AND
CHARGING
Handling Refrigerant-134a (HFC-134a)
Air conditioning systems contain HFC-134a.
This is a chemical mixture which requires special
handling procedures to avoid personal injury.
·Always wear safety goggles and protective gloves.
·Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
·If HFC-134a should come in contact with any part of
the body, flush the exposed area with cold water and
immediately seek medical help.
·If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the passenger
compartment.
·If it is necessary to fill a small HFC-134a container
from a large one, never fill the container completely.
Space should always be allowed above the liquid for
expansion.
·Keep HFC-134a containers stored below 40 ¡C (104¡F).
LEAK AT REFRIGERANT LINE CONNECTIONS
1) Check the torque on the refrigerant line fitting and, if
too loose, tighten to the specified torque.
·Use two wrenches to prevent twisting and damage
to the Line.
·Do not over tighten.
2) Perform a leak test on the refrigerant line fitting.
3) If the leak is still present, discharge and recover the
refrigerant from the system.
4) Replace the O-rings.
·O-rings cannot be reused. Always replace with
new ones.
·Be sure to apply specified compressor oil to the
new O-rings.
5) Retighten the refrigerant line fitting to the specified
torque.
·Use two wrenches to prevent twisting and damage
to the line.
6) Evacuate, charge and retest the system.
LEAK IN THE HOSE
If the compressor inlet or outlet hose is leaking, the entire
hose must be replaced. Refrigerant hose must not be cut
or spliced for repair.
1) Locate the leak.
2) Discharge and recover the refrigerant.
3) Remove the hose assembly.
·Cap the open connections at once.
4) Connect the new hose assembly.
·Use two wrenches to prevent twisting or damage
to the hose fitting.
·Tighten the hose fitting to the specified torque.
5) Evacuate, charge and test the system.

1B Ð 38 AIR CONDITIONING
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. If installing a new receiver/drier, be sure to add 30 cc
(0.8 Imp fl oz) of new compressor oil to a new one.
2. Put the receiver/drier in the bracket, and connect with
the refrigerant line. Check that no excessive force is
imposed on the line. Fasten the bracket bolt to the
receiver/drier.
3. Tighten the line to the specified torque.
Refrigerant Line Bolt Torque Nám (kgám / lbáin)
6 (0.6 / 52)
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting refrigerant line.

1B Ð 40 AIR CONDITIONING
Legend
1. Pressure Switch Connector
2. Refrigerant Line
3. Receiver / Drier
4. Radiator Grille
5. Bracket Bolt
Receiver/Drier and Associated Parts (LHD V6 without Condenser Fan)
4
2
32 51
REMOVAL
1. Disconnect the battery ground cable
2. Discharge and recover refrigerant
·Refer to ÒREFRIGERANT RECOVERYÓ in this
section.
3. Remove radiator grille.
4. Disconnect pressure switch connector.
5. Disconnect refrigerant line.
·When removing the line connected part, the
connecting part should immediately be plugged or
capped to prevent foreign matter form being mixed
in to line.
6. Remove bracket bolt.
7. Remove receiver/drier.
·Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. If installing a new receiver/drier, be sure to add
30cc(1.0 fl. oz.) of new compressor oil to a new one.
2. Put the receiver/drier in the bracket and connect with
the refrigerant line. Check that no excessive force is
imposed on the line. Fasten the bracket bolt to the
receiver/drier.
3. Tighten the refrigerant line to the specified torque.
Refrigerant Line Blot Torque Nám (kgám / lbáin)
6 (0.6 / 52)
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
875RW002

COMPRESSOR OVERHAUL 1D Ð 3
solvent, and dried with dry air. Use only lint free
cloths to wipe parts.
The operations described below are based on
bench overhaul with compressor removed from the
car, except as noted. They have been prepared in
order of accessibility of the components. When the
compressor is removed from the car for servicing,
the oil remaining in the compressor should be
discarded and new refrigerant oil added to the
compressor.
Magnetic clutch assembly repair procedures require
that the system be discharged of refrigerant. (Refer
to Section 1B for ÒREFRIGERANT RECOVERYÓ.)
Compressor malfunction will appear in one of four
ways: noise, seizure, leakage or low discharge
pressure. Resonant compressor noises are not
cause for alarm; however, irregular noise or rattles
may indicate broken parts or excessive clearances
due to wear. To check seizure, de-energize the
magnetic clutch and check to see if the drive plate
can be rotated. If rotation is impossible, the
compressor is seized. Low discharge pressure may
be due to a faulty internal seal of the compressor,
or a restriction in the compressor. Low discharge
pressure may also be due to an insufficient
refrigerant charge or a restriction elsewhere in the
system. These possibilities should be checked prior
to servicing the compressor. If the compressor is
inoperative, but is not seized, check to see if current
is being supplied to the magnetic clutch coil
terminals.
The compressor has vanes built into a rotor which
is mounted on a shaft.
When the shaft rotates, the vanes built into the
cylinder block assembly are opened by centrifugal
force.
This changes the volume of the space formed by
the rotor and cylinder, resulting in the intake and
compression of the refrigerant gas. The discharge
valve and the valve stopper, which protects the
discharge valve, are built into the cylinder block
assembly. There is no suction valve but a shaft seal
is installed between the shaft and head; a trigger
valve, which applies back pressure to the vanes, is
installed in the cylinder block and a refrigerant gas
temperature sensor is installed in the front head.
The specified quantity of compressor oil is
contained in the compressor to lubricate the various
parts using the refrigerant gas discharge pressure.
6VD1 engine is equipped with an invariable
capacity five-vane rotary compressor (DKV-14D
Type).
The compressor sucks and compresses refrigerant
by the rotation of the vane installed to the shaft,
and always discharges a fixed amount of refrigerant
independent of the load of refrigerant.The thermo sensor is installed to the front head of
the compressor to protect it by stopping its
operation when the refrigerant gas is insufficient or
when the temperature get abnormally high.
·OFF ..... 160 ±5¡C (320.0 ±9.0¡F)
·ON ..... 135 ±5¡C (275.0 ±9.0¡F)
4JG2 Engine are provided with a swash plate type
compressor (DKS-15CH Type)
Swash plate compressors have a swash (slanted)
plate mounted on the shaft. When the shaft turns,
the rotation of the swash plate is converted to
reciprocating piston motion which sucks in and
compresses the refrigerant gas.
Shaft seal (Lip type) is installed between the valve
plate and shaft & cylinder head to prevent
refrigerant gas leaks. A specified amount of
compressor oil is contained in the oil pan.
This oil is supplied to the cylinders, bearings, etc.,
by an oil pump which is connected to the swash
plate shaft.
With some compressors the differential between
the intake pressure and discharge pressure
generated while the compressor is operating is
used for lubrication instead of an oil pump.
Three pistons are arranged at 120g intervals around
the center of the swash plate shaft. These pistons
are connected to the ends of the swash plate
through shoe disks and balls.
The rotation of the swash plate causes
reciprocating movement of the piston inside the
cylinders, with each piston operating as two
cylinders. Because of that, the compressor operates
as though it has 6 cylinders.
The specified amount of the compressors oil is
150cc (4.2 Imp fl oz).
Also, compressor oil to be used varies according to
the compressor model. Be sure to avoid mixing two
or more different types of oil.
If the wrong oil is used, lubrication will be poor and
the compressor will seize or malfunction.

1D Ð 4 COMPRESSOR OVERHAUL
COMPRESSOR OIL
OIL SPECIFICATION
·The HFC-134a system requires a synthetic
(PAG) compressor oil.
·Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified
for the model of compressor.
DKV-14D : ZXL-200PG
(ISUZU PART NO.
8-97101-336-0)
DKS-15CH : ZXL-100PG
(ISUZU PART NO.
8-97101-338-0)
HANDLING OF OIL
·The oil should be free from moisture, dust,
metal powder, etc.
·Do not mix with other oil
·The water content in the oil increases when
exposed to the air. After use, seal oil from air
immediately.
·The compressor oil must be stored in steel
containers, not in plastic containers.
COMPRESSOR OIL CHECK
The oil used to lubricate the compressor is
circulating with the refrigerant.
Whenever replacing any component of the system
or a large amount of gas leakage occurs, add oil to
maintain the original amount of oil.
Oil Capacity
Capacity total in system 150cc (4.2 Imp fl oz)
Compressor (Service
150cc (4.2 Imp fl oz)
parts) charging amount
Checking and Adjusting for Used Compressor
1) Perform Oil return operation.
(Refer to ÒOil Return OperationÓ in this section.)
2) Discharge refrigerant and remove the
compressor.
3) Drain the compressor oil and measure the
extracted oil with a measuring cylinder.
4) If the amount of oil drained is much less than
90cc (2.5 Imp fl oz), some refrigerant may have
leaked out. Conduct leak tests on connections
of each system, and if necessary, repair or
replace faulty parts.5) Check the compressor oil for contamination.
(Refer to ÒContamination of Compressor OilÓ in
this section.)
6) Adjust oil level following the procedure below.
Collected Amount Charging Amount
same as collected
more than 90cc (2.5 Imp fl oz)
amount
less than 90cc (2.5 Imp fl oz) 90cc (2.5 Imp fl oz)
7) Install the compressor, then evacuate, charge
and perform oil return operation.
8) Check system operation.
When it is impossible to perform oil return
operation, the compressor oil should be checked in
the following order:
1) Discharge refrigerant and remove the
compressor.
2) Drain the compressor oil and measure the
extracted oil with a measuring cylinder.
3) Check the oil for contamination.
4) If more than 90cc (2.5 Imp fl oz) of oil is
extracted from the compressor, supply same
amount of oil to the compressor to be installed.
If the amount of oil extracted is less than 90cc
(2.5 Imp fl oz), recheck the compressor oil in the
following order:
5) Supply 90cc (2.5 Imp fl oz) of oil to the
compressor and install it onto the vehicle.
6) Perform oil return operation.
7) Remove the compressor and recheck the
amount of oil.
8) Adjust the compressor oil, if necessary.
Collected Amount Charging Amount
same as collected
more than 90cc (2.5 Imp fl oz)
amount
less than 90cc (2.5 Imp fl oz) 90cc (2.5 Imp fl oz)
GENERAL INFORMATION
871RX020

COMPRESSOR OVERHAUL 1D Ð 5
Checking and Adjusting for Compressor
Replacement
150cc (4.2 Imp fl oz) of oil is charged in compressor
(service parts). So it is necessary to drain the proper
amount of oil from the new compressor.
1) Perform oil return operation.
2) Discharge refrigerant and remove the
compressor.
3) Drain the compressor oil and measure the
extracted oil.
4) Check the compressor oil for contamination.
5) Adjust oil level as required.
Amount of oil drained Draining amount of oil
from used compressor from new compressor
less than Same as drained
90cc (2.5 Imp fl oz) amount
more than
90cc (2.5 Imp fl oz)
90cc (2.5 Imp fl oz)
6) Evacuate, charge and perform oil return
operation.
7) Check system operation.
CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a
long period of time (approximately 1 season), the
oil never becomes contaminated as long as there is
nothing wrong with the compressor or its method
of use.
Inspect the extracted oil for any of the following
conditions:
·The capacity of the oil has increased.
·The oil has changed color to red.
·Foreign substances, metal powder, etc., are
present in the oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated
compressor oil is discovered, the receiver/drier
must be replaced.
OIL RETURN OPERATION
There is close affinity between the oil and the
refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system.
When checking the amount of oil in the system, or
replacing any component of the system, the
compressor must be run in advance for oil return
operation. The procedure is as follows:
1) Open the all doors and engine hood.
2) Start the engine and A/C switch is ÒONÓ and
Set the fan control knob at its highest position.
3) Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate
the system.
4) Stop the engine.
REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply
the following amount of oil to the component parts
to be installed.
Component parts to be installed Amount of oil
Evaporator 50cc (1.4 Imp fl oz)
Condenser 30cc (0.8 Imp fl oz)
Receiver/drier 30cc (0.8 Imp fl oz)
871RX013