ISUZU TROOPER 1995 User Guide

GENERAL INFORMATION OA-7
LIFTING INSTRUCTIONS
w CAUTION:
• • If a lifting device other than the original jack is used, it is most important that the device be applied only to
the correct lifting points. Raising the vehicle
from any other point may result in serious damage.
• When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads
do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in dam­
age
or unsatisfactory vehicle performance.
LIFTING POINTS AND SUPPORTABLE POINT LOCATIONS
Long Wheel Base Model
Short Wheel Base Model
-Lifting point
~ Supportable point
·~ Fig.OA-5

OA-8 GENERAL INFORMATION
LIFTING POINT;
FRONT
• When using floor jack, lift on the center of the skid
plate (Fig. OA-6).
Fig. OA-6
SUPPORTABLE POINT; FRONT
• Position the chassis stands at the bottom of the
frame sidemember, behind
front wheel (Fig.
OA-7).
Fig. OA-7
LIFTING POINT; REAR
• Position the floor jack at the center of the rear axle
case when lifting the vehicle (Fig. OA-8).
Fig. OA-8
SUPPORTABLE POINT; REAR
• Position the chassis stands at the bottom of the
frame sidemember,
just behind the trailing link l/llllllttl
bracket (Fig. OA-9).
Fig. OA-9
SUPPORTABLE POINT; REAR
• Position the chassis stands at the bottom of the
rear
axle case (Fig. OA-10).
Fig. OA-10
Ill

GENERAL INFORMATION OA-9
STANDARD BOLTS TORQUE SPECIFICATIONS
The torque values given in the following table should be applied where a particular torque is not specified.
N·m (lb·ft)
~ Stre;.:!~ 4.8 8.8 9.8
~ Refined Non-Refined Bolt 'i-----------+------+-----+-------------l
dentification
Bolt
Diameter X Pitch (mm)
M 6X1.0
M 8X1.25
M10X1.25
*M10X1.5
M12X1.25
* M12X1.75
M14X1.5
* M14X2.0
M16X1.5
* M16X2.0
M18X1.5
M20X1.5
M22X1.5
M24X2.0
@ ® ®
ONomark 0 0
4-8 ( 3-6)
8-18( 6-13)
21 - 34 ( 15 - 25)
20 - 33 ( 14 - 25)
49 - 74 ( 36 - 54)
45 - 69 ( 33 - 51)
77 -115 ( 56 - 85)
72-107( 53-79)
104-157 ( 77-116)
100-149 ( 74-110)
151-226 (111-166)
206-310 (152-229)
251 -414 (185-305)
359-539 (265-398)
5-10 ( 4-7)
12 - 23 ( 9 - 17)
28 - 46 (
20 - 34)
28 - 45 (
20 - 33)
61 -91 ( 45 - 67)
57 - 84 ( 42 - 62)
93 -139 ( 69 - 1
03)
88 -131 ( 65 - 97)
135-204 (100-150)
130-194 ( 95-143)
195-293 (144-216)
270-405 (199-299)
363 - 544 (268 -
401)
431 -711 (318-524)
17-30 ( 12-22)
37 - 63 ( 27 - 46)
36 -
60 ( 27 - 44)
76-114 ( 56-84)
72 - 1
07 ( 53 - 79)
114 -
171 ( 84 -126)
107-160 ( 79-118)
160-240 (118-177)
153-230 (113-169)
230-345 (169-255)
317-476 (234-351)
425-637 (313-469)
554 -
831 (409 -613)
The asterisk *indicates that the bolts are used for female-threaded parts that are made of soft materials
such as casting, etc.

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

LF -Left Front
LH -Left Hand
LR-Left Rear
LS-Left Side
LWB-Long Wheel Base
L-4-In-line Four Cylinder Engine
MAF-Mass Air Flow
MAN-Manual
MAP-Manifold Absolute Pressure
Max-Maximum
MC-Mixture Control
MFI-Multipart Fuel Injection
MIL-Malfunction Indicator Lamp
Min-Minimum
mm-Millimeter
MPG-Miles per Gallon
MPH-Miles per Hour
M!f-Manual Transmission!fransaxle
MV-Millivolt
NA-Natural Aspirated
NC-Normally Closed
N·m-Newton Meters
NO-Normally Open
NOx-Nitrogen, Oxides of
OBD-On-Board Diagnostic
OD-Outside Diameter
0/D-Over Drive
OHC-Overhead Camshaft
OL-Open Loop
02-Oxygen
02S -Oxygen Sensor
PAIR-Pulsed Secondary Air Injection System
P/B-Power Brakes
PCM-Powertrain Control Module
PCV-Positive Crankcase Ventilation
PRESS-Pressure
PROM-Programmable Read Only Memory
PNP-Park/Neutral Position
P/S-Power Steering
PSI-Pounds per Square Inch
PSP-Power Steering Pressure
Pt.-Pint
Pri -Primary
PWM-Pulse Width Modulate
Ot-Quart
REF-Reference
RF -Right Front
RFI-Radio Frequency Interference
RH-Right Hand
RPM-Revolutions per Minute
RPM Sensor-Engine Speed Sensor
RPO-Regular Production Option
RR-Right Rear
RS-Right Side
RTV-Room Temperature Vulcanizing
RWAL-Rear Wheel Anti lock Brake
RWD-Rear Wheel Drive
GENERAL INFORMATION OA-11
SAE -Society of Automotive Engineers
Sec-Secondary
SFI-Sequential Multipart Fuel Injection
Sl-System International
SIR-Supplemental Inflatable Restraint System
SOHC-Single Overhead Camshaft
Sol -Solenoid
SPEC -Specification
Speedo -Speedometer
SRS-Supplemental Restraint System
ST-Start
-Scan Tool
Sw-Switch
SWB-Short Wheel Base
SYN-Synchronize
Tach-Tachometer
TB
-Throttle Body
TBI-Throttle Body Fuel Injection
TCC-Torque Converter Clutch
TCM-Transmission Control Module
TDC-Top Dead Center
Term-Terminal
TEMP-Temperature
TP-Throttle Position
TRANS-Transmission!fransaxle
TURBO-Turbocharger
TVRS-Television & Radio Suppression
TVV-Thermal Vacuum Valve
TWC-Three Way Catalytic Converter
3
AfT-Three Speed Automatic Transmission/
Transaxle
2WD-Two Wheel Drive
4 x
2-Two Wheel Drive
U-joint-Universal Joint
V-Volt(s)
VAC-Vacuum
VIN-Vehicle Identification Number
VRRRE -Vehicle Refrigerant Recovery and Recycling
Equipment
V-ref-ECM Reference Voltage
VSS-Vehicle Speed Sensor
VSV-Vacuum Switch Valve
V-6-Six Cylinder "V" Engine
V-8-Eight Cylinder "V" Engine
W-Watt(s)
w/-With
w/b -Wheel Base
w/o -Without
WOT-Wide Open Throttle

OA-12 GENERAL INFORMATION
(ISUZU IVOTORS LTD. JAPAA
VI.N. :g I ~N9_;1NE Tliifil El ~k TIRE B. COLOR/TRIMc=:::J OPTION CJ CJ CJ CJ CJ CJ
SERVICE PARTS IDENTIFICATION PLATE
Fig. OA-11
The Vehicle Information Plate (Service Parts ID
plate) is provided on all vehicle models.
It
is located on the center dash wall inside the en­
gine compartment. The
plate lists the VIN (Vehicle
Identification Number), paint information and all
production options and special equipment on the
vehicle when it was shipped from the factory (Fig.
OA-11 ).
~~---,------------------------------~4

MAINTENANCE AND LUBRICATION OB-1
SECTION 08
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule List . . . . . . . . . . . . 08-1
Explanation of Complete Vehicle
Mai-ntenance Schedule . . . . . . . . . . . . . . 08-4
Recommended
Fluids and Lubricants . . . . 08-8
Lubricant Viscosity Chart ............... 08-9
Recommended Liquid Gasket
........... 08-11
Recommended Thread Locking Agents ... 08-11
Maintenance Service Data .............. 08-12
MAINTENANCE SCHEDULE LIST
NORMAL VEHICLE USE
The maintenance instructions in this Maintenance
Schedule are based on the assumption that the vehicle
will
be used as designed:
• to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of
the glove compartment door;
• to be driven on reasonable road surfaces within
legal operating limits;
•
to be driven on a daily basis, as a general rule, for at
least several miles/kilometers;
•
to be driven on unleaded fuel
Unusual
or severe operating conditions will require
more frequent car maintenance,
as specified in the
following sections.
ITEMS
CHANGE ENGINE OIL AND OIL FIL TEA
CHANGE AUTOMATIC TRANSMISSION FLUID
SEVERE DRIVING CONDITIONS
If the vehicle is usually operated under any of the
severe driving conditions
listed below, it is
recommended that the
applicable maintenance
services be performed at the specified
interval shown
in the chart
below.
Severe driving conditions
• Repeated short trips in cold weather
• Driving in dusty areas
• Frequent idling and/or frequent low-speed
operation
• Towing a trailer
INTERVAL
Every 4,800 km (3,000 miles) or 3 months
Every
32,000 km (20,000 miles)

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

(
(
(
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 ~

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.
..