manual transmission 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

OA-6 GENERAL INFORMATION
TRANSMISSION SERIAL
NUMBER
Manual: Stamped on the left side of the trans­
mission intermediate
plate (Fig. OA-3).
Fig. OA-3
Automatic: Stamped on the identification plate, lo­
cated on the left side of the transmission
above the mode switch (Fig.
OA-4).
Fig. OA-4
ID Plate
96017587 0000 000
•

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

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.
..

OB-6 MAINTENANCE AND LUBRICATION
BRAKE SYSTEMS OPERATION
Watch for the "BRAKE" light coming on. Other
signs of possible brake trouble are such things as
repeated pulling to one side when braking, unusual
sounds
when braking or between brake
applications,
or increased brake pedal travel. If you
note one of these conditions, repair the system at
once.
For convenience, the
following should be done
when wheels are removed for rotation: Inspect lines
and hoses
for proper hookup, bindings, leaks, crack,
chafing etc.
Inspect disc brake pads for wear and
rotors
for surface condition.
Inspect other brake parts, including parking brake
drums, linings etc., at the same time. Check parking
brake adjustment.
Inspect brakes more often if habit or
conditions
result in frequent braking.
PARKING BRAKE AND TRANSMISSION
PARK MECHANISM OPERATION
Park on a fairly steep hill and hold the vehicle with
the parking brake only. This checks holding ability.
On
automatic transmission vehicles, shifting from
"P" position to the other positions cannot be made
unless
the brake pedal is depressed when the key
switch is in
"ON" position or the engine running.
WARNING
•
Before checking starter safety switch
operation below,
be sure to have enough
room around the
vehicle. Then firmly apply
both the parking brake and the regular brake.
Do not
use the accelerator pedal. If the engine
starts, be ready
to turn off the key promptly.
Take these precautions because the vehicle
could move
without warning and possibly
cause personal injury
or property damage.
STARTER SAFETY SWITCH OPERATION
(AUTOMATIC TRANSMISSION)
Check by trying to start the engine in each gear
while setting the parking brake and the foot brake.
The starter
should crank only in "P" (Park) or "N"
(Neutral).
STARTER SAFETY SWITCH OPERATION
(MANUAL TRANSMISSION)
To check, place the shift lever in "Neutral", push
the clutch pedal halfway and try to start. The starter
should not crank. The starter should crank only
when the clutch pedal is fully depressed.
ACCELERATOR LINKAGE LUBRICATION
Lubricate the accelerator pedal fulcrum pin with
chassis grease.
STEERING AND SUSPENSION
INSPECTION
Inspect front and rear suspension and steering
system
for damaged, loose or missing parts or signs
of wear. Inspect power steering lines and hoses for
proper hookup, binding, leaks, cracks, chafing, etc.
BODY AND CHASSIS LUBRICATION
Lubricate the key lock cylinders, the hood latch, the
hood and door hinges, the door check link, the
parking cable guides,
the underbody contact points,
and the linkage.
PROPELLER SHAFT INSPECTION AND
LUBRICATION
Lubricate sliding yoke and universal joints with
grease containing MOS2 (disulfide molybdenum
type grease) at the interval shown in the
Maintenance Schedule. Check for play in normal
direction of rotation of sliding yoke and universal
joints. Also check
propeller shaft flange-to-pinion
bolts for proper torque of 63 N·m (46 lb·ft) for front
and rear propeller shaft.
AUTOMATIC TRANSMISSION FLUID
INSPECTION
Check the lubricant level every 7,500 miles (12,000
km) and add lubricant
if necessary.
Under harsh operating conditions, such as constant
driving in heavy city traffic during
hot weather, or in
hilly or mountainous terrain, change the transmission
fluid and service the
sump filter after every 20,000
miles (32,000 km) of operation.
AUTO CRUISE CONTROL INSPECTION
Check to see if the clearance between cruise link and
accelerator is normal. Also check that the vacuum
hoses are routed and connected properly.
CLUTCH LINES AND HOSES INSPECTION
Check lines and hoses for proper attachment,
binding, leaks, cracks, chafing, deterioration, etc.
Any questionable parts should be replaced or
repaired at once. When abrasion or wear is evident
on lines or hoses, the cause must be corrected.
..

OB-8 MAINTENANCE AND LUBRICATION
RECOMMENDED FLUIDS AND LUBRICANTS
USAGE FLUID/LUBRICANT
Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil
(See oil
chart on the following page for
proper viscosity)
Engine
coolant Mixture of water and good quality ethylene glycol
base type antifreeze.
Brake system
DOT-3 hydraulic brake fluid.
Power steering system
DEXRON® 11-E Automatic transmission fluid.
Automatic transmission DEXRON®-III Automatic transmission fluid.
Manual transmission
Engine oil
(See oil
chart on following page for proper viscosity)
Rear
axle and front axle GL-5 gear lubricant (Standard differential)
GL-5 Limited slip differential gear lubricant (If
equipped with optional limited slip differential)
(See oil
chart in this section for proper viscosity)
Clutch system
a. Pivot points Engine oil
b. Clutch fork joint Chassis grease
c. Master cylinder DOT-3 hydraulic brake fluid
Hood latch assembly
a. Pivots and spring anchor
Engine oil
b. Release pawl Chassis grease
Hood and
door hinges
Engine oil
Chassis lubrication Chassis greae
Parking brake
cables Chassis grease
Front wheel bearings Wheel bearing grease
Free
Wheeling hubs (Automatic) Specified grease (available as service parts)
Propeller shafts
Sliding yoke and Universal joint Grease containing MoS2 or multipurpose type
grease NLGI No.2
Body
door hinge pins and linkage, fuel door hinge,
Engine oil
rear compartment lid hinges
Windshield washer solvent Washer fluid
Key lock cylinder Engine oil
Accelerator linkage
Chassis grease

MAINTENANCE AND LUBRICATION 08-9
LUBRICANT VISCOSITY CHART
Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of
lubricants according to the ambient temperature by referring to the following table.
OIL VISCOSITY CHART FOR GASOLINE ENGINE
(Single grade) VISCOSITY GRADE -AMBIENT TEMPERATURE
Fig.
OB-1
OIL VISCOSITY CHART FOR MANUAL TRANSMISSION AND TRANSFER CASE
(Single grade)
Fig.
08-2

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.