fuel filter ISUZU TROOPER 1995 Workshop Manual

(
(
(
MILEAGE/MONTHS
rn
I ffi
IN THOUSANDS
OF
MILES
(USE
ODOMETER READING)
(x 1000
miles)
~ +~
7.5 15 22.5
30
37.5 45 52.5
60
67.5
75
82.5
90
97.5
105
112.5
120 DESCRIPTION
1
CHECK
BATTERY
FLUID
LEVEL
12
2'-'.:j:
:':
';;;;;
I '' ''
,,,,,,,,,:
[}
2
CHECK
ENGINE
COOLANT
LEVEL
12
':iti:·:
(''''/''?
'';?
,,,,,,,;.;.,.,....
,,,~~
3
CHECK
BRAKE
AND
CLUTCH
FLUID
LEVEL
12
:;:;:;:;:·:·:·.
\::':\' '\"':(\':'''''''''
:'·'·'·:·.,.,,,,
d~~~~~~-------------~
)''
'"''''{''''
'}';;o;o;;
l':':':·:o·.·o·····
4
CHECK
FLUID
LEAKS
12
•.•••..••• ,,......
,,,,,,,,,,,
5
* CHANGE
ENGINE
OIL
12
:.•••:•····
f ) : •
: ; ' {
1:':''''
6
*REPLACE
ENGINE
OIL
FILTER
12
{\::::::::;
[:(o:'.
7
CHECK
COOLING
AND
HEATER
HOSES
12
I : ' :
?
,,,.,,,,,.,:,
.. ;
! • !
•••••••••.
8
CHECK
EXHAUST
SYSTEM
12
I
~
J
:
: ••;·,·····,:·:';';·
•••::::::::::·:;.;
I ;J
., ..... .
9
CHECK
FUEL
LINE
AND
FUEL
TANK/CAP
12
10
CHECK
ENGINE
DRIVE
BELTS
24
. .
I
I
11
CHECKTIRESANDWHEELS
12
li
1:;:~:
}::,
..... ::::, .. ,::,:,:,:,·····
j
12
CHECK
STEERING
OPERATION
12
1
r ., .. ,,.,,.
·
I
13
CHECK
BRAKE
LINES
AND
HOSE
12
~
~
<
.,>
/ ':'??i'
}
J
t
''}{
14
CHECK
DISC
BRAKES
12
10
}}
UL
'I I
•....
15
CHECK
BRAKE
PEDAL
PLAY
12
I"
.. )t
16
CHECK
PARKING
BRAKE
12
li
I
17
LUBE
ACCELERATOR
LINKAGE
6
,,.:
....
I
18
CHECK
SUSPENSION
AND
STEERING
12
••·•••·•··•
19
LUBE
BODY
AND
CHASSIS
6
1''''':'''''''''''
20
LUBE
FRONT
AND
REAR
PROPELLER
SHAFT 6
{:
!: • :•••••l
21
CHECK
PROPELLER
SHAFT FLANGE
TORQUE
12
•
22
*CHECK AUTOMATIC TRANSMISSION
FLUID
12
... ,, ,....
@{I{
,,,,,,,,
ttJ
·~+---------------!
23
CHECK
AUTO
CRUISE
CONTROL
LINKAGE
AND
HOSES
12
~ .
:l
!•••:
24
CHECK
CLUTCH
LINES
AND
HOSE
12
25
LUBE
CLUTCH
PEDAL
SPRING,
BUSHING
AND
CLEVIS
PIN
6
l':":"·:"ii
26
CHECK
CLUTCH
PEDAL
FREE
PLAY
12
1/JJ(
21
cHEcK sTARTER SAFETY swiTCH 12
1/,,,,.,,,,,,,,,
,,,,,,,,,
-~~~--~~~~~~-~~~~~[============J
28
CHECK
ACCELERATOR
LINKAGE
12
m ::::::::]
!•'····
'.!
Under
severe driving conditions,
additional
maintenance
is required.
Refer to
"Severe
driving
conditions".
SHADED AREA
INDICATES
SERVICE
TO
BE PERFORMED.
s: ~ 2 -1 m 2 )> 2 n m )> 2 c r­c m ::u n ~ 0 2 Q ~

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.

ENGINE DIAGNOSIS S-1
ENGINE
CONTENTS
Engine General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section S
General
Engine Mechanical .................................................... Section SA
3.2L VS Engine ............................................................... Section SA1
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section S8
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SC
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SD
Driveability and Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SE2
Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section SF
SECTION 6
ENGINE GENERAL INFORMATION
CONTENTS
Description of Engine Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-2
DESCRIPTION OF ENGINE SECTION
SECTIONS-ENGINE GENERAL INFORMATION SECTION S8-ENGINE COOLING
General description
Engine cleanliness and care, and general information
on engine service are covered in this section.
Engine diagnosis
This section covers the components of the fuel,
ignition, and mechanical systems that could cause a
particular complaint, and then outlines repairs in a
logical sequence.
SECTION SA-ENGINE MECHANICAL
This section contains information on the mechanical
parts of the engine, such as cylinder block, cylinder
head, crankshaft, pistons, valve train, camshaft, and
engine
lubrication.
Overhaul
procedures, removal and replacement
procedures, and specifications are also covered.
Specific subsections are:
SA-GENERAL;
Disassembly and reassembly procedures,
inspection and repair procedures
off the vehicle.
6A 1-3.2L V6 ENGINE;
Removal
and replacement procedures on the
vehicle.
Engine cooling system components such as radiator,
engine
coolant pump, thermostat, and cooling fan, are
covered
in this section.
SECTION SC-ENGINE FUEL
This section contains information on all the parts of the
fuel system except the fuel injectors, or throttle body II
unit itself. Items covered are: fuel tank, fuel pump, fuel
filter,
and fuel lines. Specific sections are used for each
fuel system type:
Port
Injection fuel rail and injectors will be found in
Section
6E2.
SECTION SD-ENGINE ELECTRICAL
Items covered in this section are battery, generator,
starter, ignition
coil, spark plugs and wires.
Ignition system diagnosis will be found in Section 6E2
as a "C4" chart.
Specific sections are:
601 -Battery
602 - Cranking System
603 -Charging System
604 -Ignition System

ENGINE DIAGNOSIS 6-3
HARD STARTING
1. Starting motor does not turn over
Trouble shooting procedure
Turn on headlights and starter switch.
Condition Possible cause Correction
Headlights go out or dim Battery run down or under charged Recharge or replace battery
considerably
Terminals poorly connected Clean battery posts and
terminals and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective
Headlights stay
bright Starting motor circuit open Refer to Section 6D
Starting
motor coil open Replace
2. Ignition trouble -Starting motor turns over but engine does not start
Spark Test
Disconnect a high tension cable from any spark plug. Connect the spark plug tester J-26792 (ST-1 25).
start the engine, and check if a spark is generated in the spark plug tester.
Before starting the engine, make sure
that the spark plug tester is properly grounded. To avoid
electrical shock, do not touch the high tension cable while the engine is running.
Condition Possible cause Correction
Spark jumps across gap
Spark plug defective Clean, adjust spark gap or
replace
Ignition
timing incorrect Refer to Section 6E2
Fuel not reaching fuel injector(s) or Refer to item 3
engine (Trouble
in
fuel system)
Valve
timing incorrect Adjust
Engine
lacks compression Refer to item 4
(Engine
lacks compression)
No sparking takes
place Spark plug wire disconnected or broken Connect properly or replace
Electronic Ignition System with module Replace
Poor connections in engine harness
Correct
Engine Control
Module cable Correct or replace
disconnected or defective
3. Trouble in fuel system
Condition Possible cause Correction
Starting motor turns over and
Fuel tank empty Fill
spark occurs but engine does
not start. Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective
Replace
Fuel
pump circuit open Correct or replace
Evaporative Emission Control System Correct or replace
circuit clogged
Multipart Fuel Injection System faulty Refer to "Electronic Fuel
Injection"
section

ENGINE DIAGNOSIS 6-5
ROUGH ENGINE IDLING OR ENGINE STALLING
Condition Possible cause Correction
Trouble in fuel
Idle air control valve defective Replace
injection system
Throttle shutting
off incomplete Correct or replace
Throttle position sensor circuit open
or shorted Correct or replace
Fuel injector circuits open or shorted Correct or replace
Fuel injectors damaged
Replace
Fuel pump relay defective Replace
Manifold Absolute Pressure Sensor
cable Correct or replace
disconnected
or broken
Manifold Absolute Pressure Sensor defective
Replace
Engine Coolant Temperature Sensor cable Correct
or replace
disconnected
or broken
Engine Coolant Temperature Sensor defective
Replace
Intake Air Temperature sensor cable Correct or replace
disconnected
or broken
Intake Air Temperature sensor defective
Replace
Knock Sensor
(KS) circuits open or shorted
Correct or replace
(DOHC only)
KS defective (DOHC only) Replace
KS Module circuits open or ground
Correct or replace
(DOHC only)
KS Module defective (DOHC only) Replace
Vehicle Speed Sensor circuit open or shorted
Correct or replace
Vehicle Speed Sensor defective
Replace
Trouble in emission
Engine Control Module defective
Replace
control system
Exhaust Gas Recirculation
Valve faulty
Replace
Back Pressure Transducer defective
Replace
Vacuum Switch Valve (VSV); EGR circuit
Correct
open
VSV; EGR defective Replace
Canister purge
VSV circuit open
Correct
VSV; canister circuit open
Correct
VSV; canister defective
Replace
Evaporative Emission Canister Purge control
Replace
valve defective
Trouble in ignition system
Refer
to Hard Start
Troubleshooting Guide
Others Engine lacks compression
Refer to Hard Start
Troubleshooting Guide
Valve incorrectly seated
Lap valve
Air Cleaner Filter clogged
Replace filter element
Valve timing incorrect
Readjust
Idle air control valve broken
Replace
Fast
idle solenoid defective
Replace
Positive Crankcase Ventilation valve defective
or Replace
clogged

ENGINE DIAGNOSIS 6-7
HESITATION
Condition Possible cause Correction
Hesitation on Throttle
Position Sensor adjustment incorrect Replace
throttle
acceleration valve
assembly
Throttle Position Sensor circuit open
or shorted Correct
or replace
Excessive play in accelerator linkage
Adjust or replace
Manifold Absolute
Pressure (MAP) Sensor circuit open or shorted Correct or replace
MAP Sensor defective Replace
Intake Air
Temperature (IAT) Sensor circuit open or shorted Correct or replace
Knock Sensor
(KS) Circuit open or shorted (DOHC only) Correct or replace
KS defective (DOHC only) Replace
KS Module circuits open or shorted (DOHC only) Correct or replace
KS Module defective (DOHC only) Replace
IAT Sensor defective Replace
Hesitation at
Fuel pressure
too low
high speeds
Fuel tank strainer clogged Clean or replace
Fuel pipe clogged
Clean or replace
Fuel filter clogged
Replace
Defective fuel
pump system Check and replace
Fuel Pressure Control Valve leaking Replace
Fuel injector
not working normally
Power supply or ground circuit for Multipart Fuel Injection Check and correct or
System shorted or open
replace
Distributor defective Replace
Cable of Multipart Fuel Injection System disconnected or defective Correct or replace
Engine Control Module defective Replace
Throttle Position Sensor circuit open
or shorted Correct or replace
Throttle Position Sensor defective Replace
Engine Coolant Temperature Sensor circuit open
or shorted Correct or replace
Engine Coolant Temperature Sensor defective Replace
MAP Sensor cable open
or shorted Correct or replace
MAP Sensor defective
Replace
IAT Sensor circuit open or shorted
Correct or replace
IAT Sensor defective Replace
KS Circuit open or shorted (DOHC only)
Correct or replace
KS defective (DOHC only) Replace
KS Module circuit open or shorted (DOHC only) Correct or replace
KS Module defective (DOHC only) Replace
Throttle valve
not wide opened
Check and correct or
replace
Air Cleaner Filter clogged
Replace filter element
Power supply voltage
too low Check and correct or
replace

6-8 ENGINE DIAGNOSIS
ENGINE LACKS POWER
Condition
Possible cause Correction
Trouble in fuel system Fuel Pressure Control Valve not Replace
working normally
Fuel
injector clogged Clean or replace
Fuel
pipe clogged Clean
Fuel filter clogged
or fouled Replace
Fuel
pump drive circuit not working Correct or replace
normally
Fuel tank not sufficiently breathing due Clean or replace
to clogged Evaporative Emission
Control System circuit
Water in
fuel system Clean
Inferior quality fuel
in fuel system Use fuel of specified octane
rating
Engine
Control Module supplied poor Correct circuit
voltage
Throttle
Position Sensor cable Correct or replace
disconnected or broken
Throttle Position Sensor defective Replace
Manifold Absolute
Pressure Sensor not Replace
working normally
Intake Air Temperature Sensor not Replace
working normally
Engine Coolant Temperature Sensor Correct or replace
circuit open or shorted
Engine
Coolant Temperature Sensor Replace
defective
Engine
Control Module defective Replace
Trouble
in intake or exhaust Air Cleaner Filter clogged Replace filter element
system Trouble in Induction air control valve Correct or replace
system (DOHC)
Air duct kinked or flattened Correct or replace
Ignition failure
Refer to Hard Start
Troubleshooting Guide
Heat range
of spark plug inadequate Install spark plugs of adequate
heat range
Electronic Ignition System with module Replace
•

6-12 ENGINE DIAGNOSIS
ABNORMAL COMBUSTION
Condition
Possible cause Correction
Trouble in fuel Fuel pressure control valve defective Replace
injection system
Fuel filter clogged
Replace
Fuel pump clogged Clean or replace
Fuel tank
or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel
pump relay defective
Replace
Power supply cable for fuel pump loosely connected or Reconnect, correct or
defective
replace
Manifold Absolute
Pressure Sensor circuit open or shorted Correct or replace
Manifold Absolute
Pressure Sensor defective Replace
Engine Coolant Temperature
(ECT) Sensor circuit open or Correct or replace
shorted
ECT Sensor defective
Replace
Throttle
Position Sensor adjustment incorrect Replace throttle valve
Throttle
Position Sensor defective
Replace
Throttle
Position Sensor connector loosely connected Reconnect
Vehicle Speed Sensor cable loosely connected or Correct or replace
defective
Vehicle Speed Sensor loosely fixed Fix tightly
Vehicle Speed Sensor in wrong contact or defective Replace
Engine Control Module cable
loosely connected or Correct or replace
defective
Trouble in emission
Heated
Oxygen Sensor circuit open Correct or replace
control system
Heated
Oxygen Sensor defective Replace
Vacuum Switch
Valve (VSV); Replace
Exhaust Gas Recirculation defective
Signal vacuum hose loosely fitted or defective Correct or replace
Exhaust Gas Recirculation
Valve defective Replace
Back
Pressure Transducer defective Replace
ECT Sensor circuit open or shorted Correct or replace
ECT Sensor defective Replace
Pressure Control Valve (PCV) and hose clogged Correct or replace
Evaporator system
Refer
to Section 6E
Trouble in ignition
Refer to "Engine
system Lacks
Power"
Trouble in cylinder
Carbon deposits in combustion chamber Remove carbon
head parts
Carbon deposit on valve,
valve seat and valve guide
Remove carbon
•

6-14 ENGINE DIAGNOSIS
1;:-
FUEL CONSUMPTION EXCESSIVE
Condition
Possible cause Correction
Trouble in fuel system
Mixture too rich or too lean due to Refer to "Abnormal Combus-
trouble in fuel injection system tion"
Fuel cut function does not act Refer to "Abnormal Combus-
tion"
Trouble in ignition system
Misfiring or abnormal combustion due Refer to Hard Start or
to trouble in ignition system Abnormal Combustion
Troubleshooting Guide
Others Engine idle speed too high Reset Idle Air Control Valve
Returning
of accelerator control Correct
sluggish
Fuel system leakage
Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear incorrect Caution operator of incorrect
gear selection
Excessive Exhaust
Gas Recirculation Refer to Abnormal
flow due to trouble in Exhaust Gas Combustion
Recirculation system
OIL PROBLEMS
Condition
Possible cause Correction
Oil pressure too low Wrong oil in use Replace with correct
engine
oil
Relief valve sticking Replace
Oil pump not operating
properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting-rod Replace
bearing
worn
Oil contamination Wrong oil in use Replace with new engine
oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace
gasket
Burned gases leaking Replace piston and piston rings
or rebore cylinders
Oil not reaching valve system Oil passage in cylinder head or cylinder Clean or correct
body clogged
•