air conditioning ISUZU TROOPER 1995 Workshop Manual

•:1
SECTION TABLE OF CONTENTS
. GENERAL INFORMATION OA General Information OB Maintenance and Lubrication
WORKSHOP MANUAL
HEATING AND AIR CONDITIONING 1A Heating and Ventilation
1B Air Conditioning 1D Compressor Overhaul
TROOPER
FRAME, BUMPERS AND SHEET METAL
2A Frame 2B Bumpers
(UX) 2C Sheet Metal
STEERING, SUSPENSION, WHEELS AND TIRES
3 Diagnosis 3A Front End Alignment 3B1 Power Steering Gear and Pump 3B3 Steering Linkage 3C Front Suspension 3D Rear Suspension 3E Wheels and Tires 3F4 Supplemental Restraint System Steering Wheel
FOREWORD and Column
PROPELLER SHAFT AND AXLE 4A Propeller Shaft This manual includes special notes, important points, service 4B Rear Axle
data, precautions, etc. that are needed for the maintenance, 4C Front Driving Axle
adjustments, service, removal and installation of vehicle BRAKES components. 5A Hydraulic Brakes
·~ m rmation, illustrations and specifications contained in 5A1 Brake Booster System
.. _,. 5A2 Disc Brakes ~ this ma. ~-based D.fl the latest product information 5A3 Rear Wheei_Antilock Brake System (RWAL)
available at the tirrHHrl·publication. 5A4 4-wheel Antilock Brake System (ABS)
5C Parking Brakes All rights are reserved to make changes at any time without ENGINE notice. 6· Engine General Information Arrangement of the material is shown in the table of contents &A General Engine Mechanical
on the right-hand side of this page. A black spot on the first 6A1 3.2L VB Engine
page of each section can be seen on the edge of the book &B Engine Cooling
6C Engine Fuel below each section title. These point to a more detailed table &D Engine Electrical of contents preceding each section. 6D1 Battery 6D2 Cranking System
This manual applies to 1995 models. 6D3 Charging System 6D4-Ignition System 6E2. Driveability and Emissions 6F Engine Exhaust
TRANSMISSION 7A-Automatic Transmission (4L30·E) 7B Manual Transmission 7C Clutch 7D Transfer Case
8 CHASSIS ELECTRICAL
ACCESSORIES 9A Radio 9B Cruise Control 9J Supplemental Restraint System (SRS)-AIR BAG
10 BODY
APPENDIX A CONVERSION TABLES PUBLICATION NO. UXOO-WSM-L0001-00
APPENDIXB HYDRAULIC CIRCUIT DIAGRAM (Automatic Transmission)
© 1994 ISUZU MOTORS LIMITED

GENERAL INFORMATION OA-1
GENERAL INFORMATION
CONTENTS
General Information ........................................................ /.. . . . . . . . . Section OA / Maintenance and Lubrication ............................................. ~·. . . . . . . . . . . . . Section 08
SECTION OA
GENERAL INFORMATION
CONTENTS
General repair instructions ...................... OA-1 Standard bolts torque
specifications .......... OA-9
How to use this manual. ......................... OA-2 Abbreviations
charts ............................. OA-10
Identification
....................................... OA-5 Service
parts identification plate ............... OA-12
Lifting instructions ................................ OA-7
GENERAL REPAIR INSTRUCTIONS
1. If a floor jack is used, the following precautions
are recommended.
Park
vehicle on level ground, "block" front or
rear wheels, set jack against the recommended
lifting points (see "Lifting instructions" in this
section), raise
vehicle and support with chassis
stands and then perform service operations.
2. Before performing service operations, disconnect
ground
cable from the battery to reduce the
chance
of cable damage and burning due to
short circuiting.
3. Use a cover on body, seats and floor to protect
them against damage and contamination.
4. Brake fluid and anti-freeze solution must be
handled with reasonable care, as they can cause
paint damage.
5. The use of proper tools and recommended
essential and available tools, where specified, is
important for efficient and reliable performance
of service repairs.
6. Use genuine lsuzu parts.
7. Used cotter pins, plastic clips, gaskets, 0-rings,
oil seals, lock washers and self-locking nuts
should be discarded and new ones should be
installed, as normal function of the parts cannot
be maintained
if these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in
groups. Keeping fixing
bolts and nuts separate
is
very important, as they vary in hardness and
design depending on position
of installation.
9. Clean the parts before inspection or reassembly.
Also clean oil
ports, etc. using compressed air,
and make certain
they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts
with oil or grease before installation.
11. When necessary, use a sealer on gaskets to pre­
vent leakage.
12. Carefully observe all specifications for bolt and
nut torques.
13. When removing or replacing parts that require
refrigerant
to be discharged from the air
conditioning system, be sure
to use the Vehicle
Refrigerant Recovery and Recycling Equipment
(VRRRE) to recover and recycle Refrigerant-
134a.
14. When a service operation is completed, make a
final check to be sure the service has been done
properly and the problem has been corrected.

OA-10 GENERAL INFORMATION
ABBREVIATIONS CHARTS
LIST OF AUTOMOTIVE ABBREVIATIONS WHICH MAY BE USED IN THIS MANUAL
A-Ampere(s)
ABS-Anti lock Brake System
AC-Alternating Current
A/C-Air Conditioning
ACCEL-Accelerator
ACC-Accessory
ACL-Air Cleaner
Adj-Adjust
A/F-Air Fuel Ratio
AIR-Secondary Air Injection System
Alt-Altitude
AMP-Ampere(s)
ANT-Antenna
ASM-Assembly
A/T-Automatic Transmission/Transaxle
ATDC-After Top Dead Center
ATF-Automatic Transmission Fluid
Auth -Authority
Auto -Automatic
BARO-Barometric Pressure
Bat -Battery
B+-Battery Positive Voltage
Bbl-Barrel
BHP-Brake Horsepower
BPT-Backpressure Transducer
BTDC-Before Top Dead Center
oc-Degrees Celsius
CAC-Charge Air Cooler
Calif-California
cc-Cubic Centimeter
CID-Cubic Inch Displacement
CKP-Crankshaft Position
CL-Closed Loop
CLCC-Closed Loop Carburetor Control
CMP-Camshaft Position
CO-Carbon Monoxide
Coax-Coaxial
Conn-Connector
Conv -Converter
Crank-Crankshaft
Cu.ln.-Cubic Inch
CV-Constant Velocity
Cyl-Cylinder(s)
Dl -Distributor Ignition
Diff-Differential
Dist-Distributor
DLC-Data Link Connector
DOHC-Double Overhead Camshaft
DTC-Diagnostic Trouble Code
DTM-Diagnostic Test Mode
DTT-Diagnostic Test Terminal
DVM-Digital Voltmeter (10 meg.)
DVOM-Digital Volt Ohmmeter
EBCM-Electronic Brake Control Module
ECM-Engine Control Module
ECT-Engine Coolant Temperature
EEPROM -Electronically Erasable Programmable
Read Only Memory
EGR-Exhaust Gas Recirculation
El-Electronic Ignition
ETR-Electronically Tuned Receiver
EVAP-Evaporation Emission
Exh-Exhaust
°F-Degrees Fahrenheit
Fed -
Federal (All States Except Calif.)
FF-Front Drive Front Engine
FL-Fusible Link
FLW-Fusible Link Wire
FP-Fuel Pump
FRT-Front
ft-Foot
FWD-Front Wheel Drive
4WD-Four Wheel Drive
4 x
4-Four Wheel Drive
4 A/T-Four Speed Automatic Transmission/
Transaxle
Gal-Gallon
GEN-Generator
GND-Ground
Gov-Governor
g-Gram
Harn -Harness
HC-Hydrocarbons
HD-Heavy Duty
Hg-Hydrargyrum (Mercury)
HiAit-High Altitude
H02S - Heated Oxygen Sensor
HVAC-Heater-Vent-Air Conditioning
lAC-Idle Air Control
IAT -Intake Air Temperature
IC-Integrated Circuit
-
Ignition Control
ID-Identification
-Inside Diameter
IGN-Ignition
INJ-Injection
IP-Instrument Panel
IPC-Instrument Panel Cluster
lnt-Intake
ISC-Idle Speed Control
J/B-Junction Block
kg -Kilograms
km-Kilometers
km/h -Kilometer per Hour
kPa-Kilopascals
kV-Kilovolts (thousands of volts)
kW-Kilowatts
KS -Knock Sensor
L-Liter
lb·ft-Foot Pounds
lb·in-Inch Pounds

MILEAGE
ONL
V
ITEMS MILEAGE
ONLY
ITEMS
7.5
1
CHANGE
FRONT
AND
REAR AXLE
OIL
2
CHANGE
MANUAL
TRANSMISSION
AND
TRANSFER CASE
OIL
3
REPLACE AIR
CLEANER FILTER
4
REPLACE SPARK PLUGS
5
CHANGE ENGINE
COOLANT
6
*REPLACE
TIMING
BELT
7
ROT
ATE
TIRES
8
CHANGE
POWER STEERING FLUID
9
REPACK FRONT
WHEEL
BEARINGS
10
REPACK FRONT
FREE-WHEELING HUBS
11
CLEAN
RADIATOR
CORE
AND
AIR CONDITIONING CONDENSER
12
INSPECT SPARK PLUG WIRE
'
-----
* : Replacement
of the
timing
belt
is recommended
at every
60,000
miles
(96,000
km).
Failure
to replace
the timing
belt
may
result
in damage to the engine.
)
•
IN THOUSANDS
OF
MILES
(USE
ODOMETER
READING)
15 22.5
30
37.5 45 52.5
60
67.5
75
82.5
90
97.5
'
-
'---
~--·-L....
SHADED AREA
INDICATES SERVICE TO
BE
PERFORMED.
)
105
112.5
120 '-------
(x 1000
miles)
DESCRIPTION ------
)
0 ~ s: l> ~ z l> z 0 m l> z c r­c m :a c; ~ 0 2

OB-4 MAINTENANCE AND LUBRICATION
EXPLANATION OF COMPLETE VEHICLE
MAINTENANCE
SCHEDULE
Brief explanations of the services listed in the
preceeding Maintenance Scheduled are presented
below.
Replace
all questionable parts and note any necessary
repairs
as you perform these maintenance
procedures.
FRONT AND REAR AXLE LUBRICANT
REPLACEMENT
Check the lubricant level after every 7,500 miles
(12,000 km) of operation and add lubricant to level
of filler hole if necessary.
Replace the front and rear
axle lubricant at 15,000
miles (24,000 km) and 30,000 miles (48,000 km) and
after every 30,000
miles (48,000 km) or operation
thereafter.
MANUAL TRANSMISSION LUBRICANT
REPLACEMENT
Check the lubricant level after every 7,500 miles
(12,000 km) of operation and add lubricant to level
of filler hole if necessary.
Replace the transmission
lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000
miles (48,000 km) of operation there­
after.
TRANSFER CASE LUBRICANT
REPLACEMENT
Check the lubricant level after every 7,500 miles
(12,000 km) of operation and add lubricant to level
of filler hole if necessary.
Replace
the transfer case lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000
miles (48,000 km) of operation there­
after.
AIR CLEANER ELEMENT REPLACEMENT
Replace the air cleaner under normal operating
conditions every 30,000 miles (48,000 km).
Operation
of the vehicle in dusty areas will
necessitate more frequent replacement.
SPARK PLUG REPLACEMENT
Replace the plugs at 30,000 mile (48,000 km) intervals
with the type specified at the end of this section.
COOLING SYSTEM SERVICE
Drain, flush and refill system with new engine coolant.
Refer
to "Recommended Fluids and Lubricants" in
this section,
or ENGINE COOLING (SEC. 68).
TIMING BELT REPLACEMENT
Replacement of the timing belt is recommended at
every 60,000 miles (96,000 km).
Failure
to replace the timing belt may result in serious
damage
to the engine.
TIRE ROTATION
Rotate tires every 7,500 miles (12,000 km).
POWER STEERING FLUID REPLACEMENT
Drain the power steering fluid and then refill the
system
to the proper level with power steering fluid
after every 30,000 miles (48,000 km) of operation.
See the appropriate section
of this manual for further
details.
FRONT WHEEL HUBS LUBRICANT
REPLACEMENT
Clean and repack the front wheel bearings at 30,000
mile (48,000 km) intervals.
Clean and lubricate the free wheeling hubs at the
same
time the front wheel bearings are serviced.
Refer
to FRONT DRIVING AXLE (SEC. 4C).
RADIATOR CORE AND AIR CONDITIONING
CONDENSER CLEANING
Clean the front of the radiator core and air con­
ditioning condenser, at 60,000 mile (96,000 km)
intervals.
SPARK PLUG WIRE INSPECTION
Check the spark plug wires at 60,000 mile (96,000 km)
intervals.
..

FLUID LEVEL CHECK
A fluid loss in any system (except windshield
washer) may indicate a problem. Repair the system
at once.
Engine
oil level -Check level and add if
necessary. The best time to check the engine oil
level is
when the oil is warm. After stopping the
engine with the vehicle on a level surface, wait a
few minutes for the oil to drain back to the oil pan.
Pull
out the oil level indicator (dipstick). Wipe it
clean and push the oil level indicator back down all
the
way. Pull out the oil level indicator, keeping the
tip down, and look at the oil level on it.
Add oil, if needed, to keep the oil level above
the
"ADD" mark and between the "ADD" and
"FULL" marks in the operating range area. Avoid
overfilling the engine since this may cause engine
damage. Push
the oil level indicator back down all
the
way after taking the reading.
If you check the oil level when the oil is cold, do
not run the engine first. The cold oil will not drain
back
to the pan fast enough to give a true oil level.
Engine coolant level and condition -Check
engine coolant level in the coolant reservoir and
add engine
coolant if necessary. Inspect the engine
coolant and replace it if dirty or rusty.
Windshield washer fluid level -Check washer
fluid level in reservoir and add if necessary.
Power steering system reservoir level-Check
and keep at
proper level.
Brake master cylinder reservoir level -Check
fluid. Keep fluid at proper level. A low fluid level
can indicate
worn disc brake pads which may need
to be serviced.
Hydraulic clutch system -Check fluid l~vel in
the reservoir.
Add fluid as required.
Battery fluid level -Check fluid level in the
battery.
FLUID LEAK CHECK
Check for fuel, water, oil or other fluid leaks by
looking at the surface beneath the vehicle after it
has been parked for a while. Water dripping from
the air conditioning system after use is normal. If
you notice gasoline fumes or fluid at any time,
locate the source and correct it at once.
ENGINE OIL AND OIL FILTER
REPLACEMENT
Always use API SE, SF, SG, SH or ILSAC GF-1
quality oils of the proper viscosity.
When choosing an oil, consider the range of
temperatures the car will be operated in before the
next oil change. Then, select the recommended oil
viscosity
from the chart (Fig. OB-1).
Always change the oil and the oil filter as soon as
possible after driving in a dust storm.
MAINTENANCE AND LUBRICATION OB-5
ENGINE COOLING SYSTEM INSPECTION
Inspect coolant/anti-freeze. If coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep
coolant at the proper mixture for proper freeze
protection,
corrosion inhibitor level and best engine
operating temperature.
Inspect hoses and replace if
cracked, swollen or deteriorated. Tighten hose
clamps if equipped with screw-type clamps. Clean
outside of radiator and air conditioning condenser.
Wash
filler cap and neck. To help ensure proper
operation, a pressure test of both the cooling
system and cap is also recommended.
EXHAUST SYSTEM INSPECTION
Visually inspect the exhaust pipes, muffler, heat
shields and hangers
for cracks, deterioration, or
damage.
Be alert to any changes in the sound of the exhaust
system
or any smell of fumes. These are signs the
system may be leaking or overheating. Repair the
system at once,
if these conditions exist. (See also
"Engine Exhaust Gas Safety" and "Three Way
Catalytic Converter" in Owner's manual.)
FUEL CAP, FUEL LINES, AND FUEL TANK
INSPECTION
Inspect the fuel tank, the fuel cap and the fuel lines
every
60,000 miles (96,000 km) for damage which
could cause leakage.
Inspect the fuel cap and the gasket for correct sealing
and physical damage. Replace any damaged parts.
DRIVE BELT INSPECTION
Check the belts driving the steering oil pump, the air
conditioning compressor, and the generator
for
cracks, fraying, wear, and correct tension every 30,000
miles (48,000 km). Adjust or replace as necessary.
WHEEL ALIGNMENT, BALANCE AND
TIRES OPERATION
Uneven or abnormal tire wear, or a pull right or left
on a straight and level road may show the need for
a wheel alignment. A vibration of the steering
wheel or seat at normal highway speeds means a
wheel balancing is needed. Check tire pressure
when the tires are "cold" (include the spare).
Maintain pressure as shown in the tire placard,
which is located on the driver's door lock pillar.
STEERING SYSTEM OPERATION
Be alert for any changes in steering action. An
inspection
or service is needed when the steering
wheel is harder
to turn or has too much free play, or
if there are unusual sounds when turning or parking.

MAINTENANCE AND LUBRICATION OB-13
APPROXIMATE CAPACITIES
Items Metric Measure U.S. Measure
Fuel tank 85L 22.5 Gal.
*Crankcase
Oil Change with Filter .............................. 5.4L 5.7 at
Oil Change without Filter ••••••••••••••••••\
0 •••• 0 ••• 4.7L
5.0 at
Coolant ........................................ MIT 8.8L 9.3 at
A/T 8.5L 9.0 at
Transmission
Manual
.......................................... 2.95L 3.1 at
Automatic ••••••••••••••••••\
•• 0 •••• 0 0 0 ••••••••••• 8.6L 9.1 at
Transfer
1.45L 1.5 at
Axle
Rear o o o 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I 0 0 0 o o o o o o o 0 0 0 0 0 0 0 0 0 0 0 o o 1.8L 1.9 at
Front ........................................ ~ ... 1.5L 1.6 at
Power steering ••• 0 ••••••••• 0 ••••••••••••••••••\
0 •••• 1.0L 1.1 at
Air conditioning (R-134a) o o 0
0 0 0 0 0 0 0 0 I 0 0 0 0 0 o o 0 o 0 0 0 0 0 0 0 0.75kg 1.651b
* Crankcase capacities shown are approximate refill capacities.
After
refill, recheck oil level.

HEATING AND VENTILATION 1A-1
HEATING AND AIR CONDITIONING
CONTENTS
Heating and Ventilation .................................................... Section 1A
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 B
Compressor Overhaul. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 D
SECTION 1A
HEATING AND VENTILATION
CONTENTS
General Description .................... 1A-2 On-Vehicle Service ..................... 1A-11
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A-2 Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . 1A-11
Control Lever Assembly . . . . . . . . . . . . . . . 1 A-3 Heater Core and/or Mode Door ......... 1A-12
Ventilation .......................... 1A-3 Heater Mode Control Link Unit ......... 1A-14
Air Select Knob . . . . . . . . . . . . . . . . . . . . . . 1 A-4 Heater Temperature Control Link Unit ... 1A-15
Air Source Select Lever ............... 1A-4 Blower Assembly .................... 1A-16
Fan Control Knob .................... 1A-4 Blower Link Unit and/or Mode Door . . . . 1A-17
Temperature Control Knob ............ 1A-4 Blower Motor ....................... 1A-18
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Rear Heater Duct, Defroster Nozzle
Diagnosis ............................. 1A-6 and Ventilation Duct ............... 1A-19
.. # Heating Cycle Diagnosis ............... 1A-6 Center and/or Driver Side Vent ......... 1A-20
Fan Control Lever (Fan Switch) Control Lever Assembly
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 1 A-7 and/or Control Cables .............. 1A-21
Individual Inspection ................. 1A-10 Control Panel Illumination Bulb ........ 1A-23
Resistor ............................ 1A-23

1A-2 HEATING AND VENTILATION
GENERAL DESCRIPTION
HEATER
When the engine warming up, the warmed engine
coolant is sent out into the heater core. The heater
system
supplies warm air into the passenger
compartment to warm it up.
Outside air is
circulated through the heater core of
the heater unit and then back into the passenger
compartment. By
controlling the mixture of outside
air and heater core air, the
most comfortable
passenger compartment temperature can be
selected and maintained.
The temperature
of warm air sent to the passenger
compartment is controlled by the temperature
control knob. This knob acts to open and close the
air
mix door, thus controlling the amount of air
passed through the heater core.
Defroster nozzle
Side
def hose
The air selector knob, with its different modes, also
allows
you to select and maintain the most
comfortable passenger compartment temperature.
The air source
select lever is used to select either
"FRESH" for the introduction of the outside air, or
"CIRC" for the circulation of the inside air. When the
lever is set to "FRESH", the outside air is always
taken into the passenger compartment. When
setting the
lever to "CIRC" position, the circulation
of air is restricted only to the inside air with no
introduction
of the outside air and the air in the
passenger
compartment gets warm quickened.
However, the
lever is normally set to "FRESH" to
prevent the windshield from clouding.
Upper center vent duct
A/C-Air Conditioning Lower
center vent duct
<
Heater unit
Duct
Fig. 1A-1
Blower
assembly
Evaporator assembly
Control lever assembly
W/0 A/C
/'

CONTROL LEVER ASSEMBL V
The vehicle has cable-control-type to control by
cable the mode and temperature of the heater unit
and the mode door for the air source of the blower
assembly.
HEATING AND VENTILATION 1A-3
The fan control is used to control the amount of air
sent
out by the registor at four levels from "LOW"
to "HIGH".
Temperature control knob Air source select lever Air select knob
A/C switch (WI A/C) Fan control knob (Fan switch)
A/C-Air Conditioning
Fig. 1A-2
,__,.. VENTILATION
Set "AIR SOURCE SELECT LEVER" to "FRESH"
position and turn on the blower fan. Heating can be
done in this
lever position, sending in fresh air
from outside. The
blower fan also serves
to deliver fresh outside
air
to the vehicle interior to assure adequate
ventilation.
Fig. 1A-3