inflation pressure ISUZU TROOPER 1995 Workshop Manual

OB-12 MAINTENANCE AND LUBRICATION
MAINTENANCE SERVICE DATA
SERVICE DATA AND SPECIFICATIONS
ENGINE
• Valve clearance I o o I I I 0 0 0 I 0 o o o o o I 0 o o o 0 0 o o o o Zero (Hydraulic adjuster)
• Spark plug type I I o 0 I o 0 I I I 0 o o o I 0 I o o 0 0 0 o o 0 0 0 FR2LS, BKR6E-1 1, K20PR-U11 or equivalent
•
Spark plug gap ............................ 1.05 mm (0.04 in)
• Drive belt tension ..........................
(with a belttension gage)
Generator belt 170-190 lb 100-120 lb
PIS
pump belt 70-110 lb 70-110 lb
A/C compressor belt 100-140 lb 80-120 lb
CLUTCH
• Clutch pedal free play ......................... 5 -15 mm (0.20 -0.59 in)
BRAKE
• Brake pedal free play o o o o o o o o 0 0 o o o o o 0 0 o o 0 I o o o o 6 -10 mm (0.24 -0.39 in)
• Parking brake travel ••••••••••••••••••\
•• 0 ••••• 6-7 notches
WHEEL
ALIGNMENT
•
Toe-in 0 0 o o 0 0 I 0 0 o o o o 0 0 0 0 o o o o I 0 0 o o 0 0 o o o o 0 I 0 0 ± 2 mm (0 ± 0.08 in)
• Camber .................................. oo ± 30'
•
Caster o o o 0 0 0 0 o o o o o o I 0 0 o o o o 0 0 o o o o 0 o o o o o 0 0 o 2° 1 0' ± 45' (Long wheel base model)
2° 00' ± 45' (Short wheel base model)
PROPELLER SHAFT
• Flange torque ••••••••••••••••••\
•• 0' ••• 0 ••• 63 N·m (46 lb·ft)
WHEEL AND TIRES
• Wheel nut torque o o o o 0 0 o o o o o o o o o o o I o o o o 0 0 0 o 118 N·m (87 lb·ft)
* • Tire inflation pressure •••••••••••••• 0 ••• Front 21 0 kPa (30 psi)
Rear
240 kPa (35 psi)
* Unless otherwise specified on tire information label on vehicle.
~~-.... ¢ .............. .-I ~ -.,~iii~-..--. ....... 2 ........ -. .................. ~~ - I

DIAGNOSIS 3-9
TIRE DIAGNOSIS
• Hard cornering • Incorrect wheel alignment • Heavy acceleration
from a
stop • Under inflation
• Tire unevenly worn
• Lack of rotation • Over inflation
Fig. 3-1
IRREGULAR AND PREMATURE WEAR
(Fig. 3-1)
Irregular and/or premature wear has many causes.
Some of them are incorrect inflation pressures, lack of
tire rotation, poor driving habits or improper wheel
alignment. Incorrect inflation
is common cause of tire
premature wear.
NOTE:
Due to their design, radial tires tend to wear faster in
the
shoulder area, particularly on the front tires. This
makes
regular rotation especially necessary. After
rotation,
be 'Sure to check wheel nut torque, and set tire
pressures.
TIRE ROTATION (Fig. 3-2)
Tire rotation is recommended to equalize wear for
longer tire life.
Acceptable rotation patterns
Fig. 3-2
Spare tire
If the following conditions are noted, rotate the tires:
• Front tire wear is different from rear.
• Uneven wear exists across the tread of any tire.
• Left and right front tire wear is unequal.
•
Left and right rear tire wear is unequal.
Check wheel alignment if the following conditions are
noted:
• Left and right front tire wear is unequal.
•
Wear is uneven across the tread of any front tire.
• Front tire treads have a scuffed appearance with
"feather" edges on one side of the tread ribs or
blocks.
TREAD WEAR INDICATORS (Fig. 3-3)
The original equipment tires have built-in tread wear
indicators to show when tires need replacement.
These indicators may appear as wide bands. When the
indicators appear in
two or more grooves at three
locations, tire replacement is recommended.
Fig. 3-3
Tread wear
indicators

FRONT END ALIGNMENT 3A-3
ON-VEHICLE SERVICE
INSPECTION
Before making any adjustments affecting caster,
camber or toe-in, the following front end inspection
should be made.
I L•IINSPECT
1. Tires for proper inflation pressure. Refer to
"Wheels and Tires" in section 3E.
2. Front wheel bearings for proper adjustment.
Refer to "Front Wheel Drive" in section 4C.
3. Ball joints, tie rod ends and relay rods. If
excessive looseness is noted, correct before
adjusting. Refer
to "Steering Linkage" in section
3B3.
4. Wheel and tires for run-out. Refer to "Wheels
and Tires" in section 3E.
5. Trim height. If not within specifications, the
correction
must be made before adjusting caster.
6. Steering gear for looseness at the frame.
7. Shock absorbers for leaks or any noticeable
noise.
Refer
to "Front Suspension" in section 3C.
8. Control arms or stabilizer bar attachment for
looseness. Refer to "Front Suspension" in section
3C.
9. Alignment equipment. Follow the manufacturer's
instructions.
10. Level of the vehicle. The vehicle must be on a
level surface.
TRIM HEIGHT ADJUSTMENT
Adjust the trim height by means of the adjusting bolt
on the height control arms (Fig. 3A-4 and 5).
W CAUTION:
When adjusting front end alignment, be sure to
begin with trim height as trim height adjustment
may change other adjusted alignments.
1. Check and adjust the tire inflation pressures.
2. Park the vehicle on a level ground and move the
front of the vehicle up and down several times to
settle the suspension.
3. Make necessary adjustment with the adjusting
bolt on the height control arms.
WHEEL
ALIGNMENT SPECIFICATION
Trim height (Z) 129 mm (5.08 in)
Lower
ball joint
B
Fig. 3A-4
Fig. 3A-5
CASTER ADJUSTMENT
Level ground
The caster angle can be adjusted by means of the
caster shims installed between the chassis frame and
fulcrum pins (Fig. 3A-6 and 7).
WHEEL
ALIGNMENT SPECIFICATION
LWB
Caster angle
SWB
W CAUTION:
Left and right side to be equal within 30'
NOTE:
Difference of the caster shim front/rear thickness shall
be 3.6
mm (0.142 in) or less. Overall thickness of caster
shim and camber shim shall be 10.8 mm (0.425 in) or
less.

WHEELS AND TIRES 3E-1
SECTION 3E
WHEELS AND TIRES
W CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Fasteners
that are not reused, and those requiring thread locking compound, will be called out. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 E -1 Unit Repair .......................................... 3E-7
Diagnosis ........................................... 3E-2 Tires ............................................... 3E-7
Irregular and Premature Wear ................ 3E-2 Wheels ............................................ 3E-7
Inflation of Tires ................................. 3 E- 3 General Balance Procedure ................... 3E-8
Diagnosis List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 E- 3 Balancing Wheel and Tire ...................... 3E-8
On-Vehicle Service ................................ 3E-6 Main Data and Specifications .................... 3E-9
Wheels ............................................ 3E-6 General Specifications ......................... 3E-9
Torque Specifications .......................... 3E-9
GENERAL DESCRIPTION
Replacement wheels or tires must be equivalent to
the originals in load capacity, specified dimension
and mounting configuration. Improper size or type
may affect bearing life, brake performance,
speedometer/odometer calibration, vehicle ground
clearance and tire clearance to the body and chassis.
p 245
T Tire type P -Passenger T -Temporary C -Commercial
Section
width (Millimeters) 215 225
245
ETC.
Metric tire sizes 70 R 16 T ,...
Aspect ratio I Rim diameter
(Section height)
(Section
width) X 100 (Inches)
14 60 70
80 ETC.
15
16 ETC.
Construction type
R-Radial
B - Bias-belted
D - Diagonal (Bias)
METRIC TIRE SIZE FORMAT
All model are equipped with metric sized tubeless
steel belted radial
tires. Correct tire pressures and
driving habits have an important influence on tire life.
Heavy cornering, excessively rapid acceleration and
unnecessary sharp braking increase
premature and
uneven wear.
16 X 7 JJ
I
~pe of flange
Rim width 5% 5.5 in.
6 6.0 in. 7 7.0 in.
Rim diameter Rim width
14 14 in. 15 15 in. 16 : 16 in.
I Off Set RIM SIZE FORMAT
Fig. 3E-1

3E-2 WHEELS AND TIRES
DIAGNOSIS
• Hard cornering • Incorrect wheel alignment
• Heavy acceleration from a stop • Under infration • Tire unevenly worn • Lack of rotation • Over inflation
Fig. 3E-2
IRREGULAR AND PREMATURE WEAR
(Fig. 3E-2)
Irregular and/or premature wear has many causes.
Some of them are incorrect inflation pressures, lack of
tire rotation, poor driving habits or improper wheel
alignment. Incorrect inflation
is common cause of tire
premature wear.
NOTE:
Due to their design, radial tires tend to wear faster in
the
shoulder area, particularly on the front tires. This
makes
regular rotation especially necessary. After
rotation, be sure to check wheel nut torque, and set tire
pressures.
TIRE ROTATION
Tire rotation is recommended to equalize wear for
longer tire life (Fig. 3E-3).
Acceptable rotation patterns
Fig. 3E-3
Spare tire
If the following conditions are noted, rotate the tires:
• Front tire wear is different from rear.
• Uneven wear exists across the tread of any tire.
• Left and right front tire wear is unequal.
•
Left and right rear tire wear is unequal.
Check wheel alignment if the following conditions are
noted:
• Left and right front tire wear is unequal.
•
Wear is uneven across the tread of any front tire.
• Front tire treads have a scuffed appearance with
"feather" edges on one side of the tread ribs or
blocks.
TREAD WEAR INDICATORS (fig. 3E-4)
The original equipment tires have built-in tread wear
indicators to show when tires need replacement.
These indicators may appear as wide bands. When the
indicators appear in
two or more grooves at three
locations, tire replacement is recommended.
Fig. 3E-4
Tread wear
indicators
•

INFLATION OF TIRES
Tire pressure, in cold condition (after vehicle has setfor
three hours or more, and driven less than one mile),
should
be checked monthly or before any extended
trip. Tire pressure increases
approximately 15% when
the tires become hot during driving. Tire pressure
specification is shown on the
label located on the left
door lock pillar (Fig. 3E-5).
Fig.
3E-5
NOTE:
Check the tire pressure whenever irregular wear is
found. Tire
inflation greatly affects tire wear. If the
alignment check does not reveal any alignment
problems,
check the condition of the shock absorbers
and
wheel/tire balance.
WHEELS AND TIRES 3E-3
DIAGNOSIS LIST
If the following conditions are noted, rotation is
required.
1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left and right front tire wear is unequal.
4. Left and right rear tire wear is unequal.
If
the following conditions are noted, check the wheel
alignment.
1. Left and right front tire wear is unequal.
2. Uneven wear exists across the tread of any tire.
3. Front tire treads have scuffed appearance with
"feather" edges on one side of tread ribs or
blocks.
4. There is cupping, flat spotting etc.
Higher than recommended pressure can cause:
1. Hard ride.
2. Poor steering stability.
3. Rapid and uneven wear at center of the tread.
Lower than recommended pressure can cause:
1. Tire squeal on turns.
2. Hard steering.
3. Rapid and uneven wear on the edges of the tread.
4. Tire rim bruises and rupture.
5. Tire cord breakage.
6. High tire temperatures.
7. Reduced handling.
8. Reduced fuel economy.
Unequal pressure on same axle can cause:
1. Uneven braking
2. Steering lead.
3. Reduced handling.
4. Swerve on acceleration

WHEELS AND TIRES 3E-1
TIRES
REPLACEMENT
UNIT REPAIR
WHEELS
REPLACEMENT
When replacement is necessary, the original metric
the size should be used. Most metric tire sizes do not
have exact corresponding alphanumeric tire sizes. It
is recommended that new tires be installed in pairs on
the same axle. If necessary to replace only one tire, it
should be paired with tire having the most tread, to
equalize braking traction.
w CAUTION:
Do not mix different types of tires such as radial,
bias and bias-belted tires except in emergencies,
because
vehicle handling may be seriously
affected and may result in loss of control.
TIRE DISMOUNTING
Remove valve cap on valve step and deflate the tire.
Then use a
tire changing machine to mount or
dismount tires.
Follow the equipment manufacturer's instruction. Do
not use hand tools or tire lever alone to change tires
as they may damage the tire beads or wheel rim.
TIRE MOUNTING
Rim bead seats should be cleaned with a wire brush
....._., or coarse steel wool to remove lubricants, and light
rust. Before mounting a tire, the bead area should be
well lubricated with an approved tire lubricant.
After mounting, inflate the tire to 196kPa (28 psi) so
that beads are completely seated. Inflate the air to
specified pressure and install valve cap to the stem.
\f WARNING:
Never stand over tire when inflating. Bead may
break when bead snaps over rim's safety hump
and cause serious personal injury.
Never exceed
240 kPa (35 psi) pressure when
inflating. If 240 kPa (35 psi) pressure will not
seat beads, deflate, re-lubricate and re-inflate.
Over
inflation may cause the bead to break and
cause serious
personal injury.
TIRE REPAIR
There are many different materials on the market
used to repair tires.
Manufacturers have published detailed instructions
on how and when to repair tires. These instructions
can be obtained from the tire manufacturer if they are
not included with the repair kit. Damaged
wheels and wheels with excessive run-out
must be replaced.
Fig. 3E-10
Wheel
run-out at rim
Steel Aluminum
@ Vertical play: 1.5 (0.059) 0.7
(0.028) Less than mm(in)
@ Horizontal play: 1.5 (0.059) 0.7
(0.028) Less than mm(in)

3E-8 WHEELS AND TIRES
GENERAL BALANCE PROCEDURE
Deposits of mud, etc. must be cleaned from the inside
of the rim.
The tire should be inspected
for the following: match
mount paint marks, bent rims, bulges, irregular tire
wear, proper
wheel size and inflation pressure. Then
balance according to the equipment manufacturer's
recommendations.
There are
two types of wheel and tire balance.
Static balance is the equal distribution
of weight
around the wheel.
Assemblies
that are statically unbalanced cause a
bouncing action
called tramp. This condition will
eventually
cause uneven tire wear (Fig. 3E-11 ).
Dynamic balance is the equal distribution of weight on
each side
of the wheel center-line so that when the tire
spins there
is no tendency for the assembly to move
from side to side. Assemblies that are dynamically
unbalanced may cause shimmy (Fig. 3E-12).
Heavy spot wheel shimmy
Heavy spot wheel tramp
WARNING
Add balance weights here
Corrective weights
Fig. 3E-11
Add balance
weights here
Corrective weights
Fig. 3E-12
Stones should
be removed from the tread to
avoid operator injury during spin balancing and
to obtain a
good balance.
BALANCING WHEEL AND TIRE
ON-VEHICLE
BALANCING
On-Vehicle balancing methods vary with equipment
and tool manufacturers. Be sure to follow each
manufacturer's instructions during balancing
operation.
OFF-VEHICLE BALANCING
Most electronic off-vehicle balancers are more
accurate than the on-vehicle spin balancers. They are
easy to use and give a dynamic balance. Although
they
do not correct for drum or disc unbalance (as on­
vehicle
spin balancing does), they are very accurate
(Fig. 3E-13).
Fig. 3E-13

HYDRAULIC BRAKES 5A-3
DIAGNOSIS OF BRAKE SYSTEM
Condition
Possible Cause Correction
Brake
Pull 1. Tire inflation pressures unequal. 1. Adjust
2. Front wheel alignment incorrect. 2. Adjust
3. Unmatched tires on same axle. 3. Tires with approx. the same amount of
tread should be used on the same axle.
4. Restricted brake pipes or hoses. 4. Check for soft hoses and damaged
lines. Replace with new hoses and new
double-walled steel brake piping.
5. Water or oil on brake pads. 5. Clean or replace.
6. Brake pads hardened. 6. Replace.
7. Brake pads worn excessively. 7. Replace.
8. Brake rotor worn or scored. 8. Grind or replace.
9. Disc brake caliper malfunctioning. 9. Clean or replace.
10. Front hub bearing preload incorrect. 10. Adjust or replace.
11. Loose suspension parts. 11. Check all suspension mountings.
12. Loose
calipers. 12. Check and tighten bolts to specifi-
cations.
Brake 1. Excessive lateral runout. 1. Check per instructions.
Roughness-or If not within specifications, replace or
Chatter machine the rotor.
(Pulsates) 2. Parallelism not within specifications. 2. Check per instructions.
If not within specifications, replace or
machine the rotor.
3. Wheel bearings not adjusted. 3. Adjust wheel bearings to correct
specifications.
4. Pad reversed (steel against iron). 4. Replace brake pad and machine rotor
to within specifications.
Excessive Pedal 1. Malfunctioning vacuum booster. 1. Check vacuum booster operation and
Effort repair, if necessary.
2. Partial system failure. 2. Check front and rear brake system for
failure and repair. Also, check brake
warning
light. If a failed system
is
found, the
light should indicate a
failure.
3. Excessively worn pad. 3. Check and replace pads in sets.
4. Piston in caliper stuck or sluggish. 4. Remove caliper and rebuild.
5. Fading brakes due to incorrect pad. 5. Remove and replace with original
equipment pad or equivalent.
6. Vacuum leak to vacuum booster. 4. Check for ruptured or loose hose.
7. Check direction of check valve within 5. Correct vacuum hose direction.
vacuum hose.
8. Grease on the brake pads. 6. Replace or clean.
Excessive Brake 1. Air in hydraulic circuit. 1. Bleed hydraulic circuit.
Pedal Travel 2. Level of brake fluid in reservoir too low. 2. Replenish brake fluid reservoir to speci-
fied
level and bleed hydraulic circuit as
necessary.
3. Master cylinder push rod clearance ex-3. Adjust.
cessive.
4. Leakage in hydraulic system. 4. Correct or replace defective parts.

ENGINE DIAGNOSIS 6-9
ENGINE LACKS POWER (Cont'd)
Condition Possible cause Correction
Engine overheating
Level of Engine Coolant too low Replenish
Thermo switch or fan motor defective Replace
Thermostat defective Replace
Engine
Coolant pump defective Correct or replace
Radiator clogged
Clean or replace
Radiator
filler cap defective Replace
Level
of oil in engine crankcase too low Change or replenish
or
wrong oil engine
Resistance in exhaust system
Clean exhaust system or
increased replace
defective parts
Throttle Position Sensor adjustment Adjust
Wide Open Throttle
incorrect switch setting
Throttle Position Sensor circuit open
or Correct or replace
shorted
Cylinder head gasket damaged Replace
Engine overcooling
Radiator
overcooling Install cover
in front of
radiator
Thermostat defective Replace
(Use a thermostat set
to open at a2·c (180.F))
Engine
lacks compression Refer to Hard Start
Others Tire inflation pressure
abnormal Adjust to recommend
pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level
of oil in engine crankcase too Correct level of engine oil
high
Exhaust Gas
Recirculation Valve Replace
defective
Back pressure transducer defective
Replace