oil capacity ISUZU TROOPER 1995 Workshop Manual

COMPRESSOR OVERHAUL 10-3
GENERAL INFORMATION
COMPRESSOR OIL
OIL SPECIFICATION
• The HFC-134a system requires a synthetic
(PAG) compressor oil whereas the R-12 system
requires a
mineral compressor oil. The two oils
must never be mixed.
• Compressor (PAG) oil varies according to com­
pressor model. Be sure to use oil specified for
the model of compressor.
• Always use HFC-134a Vane Rotary Type Com­
pressor Oil
(AIPDN Part No. 2-90188-301-0)
HANDLING OF OIL
• The oil should be free from moisture, dust,
metal powder, etc.
• Do not mix with other oil.
•
The water content in the oil increases when
exposed to the air. After use, seal oil from air
immediately.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)
•
The compressor oil must be stored in steel
containers, not in plastic containers.
COMPRESSOR OIL CHECK
The oil used to lubricate the compressor is circul­
ating with the refrigerant.
Whenever replacing any component of the system
or a large amount of gas leakage occurs, add oil to
maintain the original amount of oil.
Oil Capacity.
Capacity
total in system 150cc (5.0 fl.oz.)
Compressor (Service
parts)
charging amount 15 0cc (5
·0
fl.oz.)
Checking and Adjusting for Used Compressor
1. Perform Oil return operation.
(Refer to "Oil Return Operation" in this section.)
2. Discharge and recover refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the
extracted oil with a measuring cylinder (Fig. 1 D-
2).
Fig. 1D-2
4. If the amount of oil drained is much less than
90cc (3.0 fl.oz.), some refrigerant may have
leaked out. Conduct leak tests on connections of
each system, and if necessary, repair or replace
faulty parts.
5. Check the compressor oil for contamination.
(Refer to "Contamination of Compressor Oil" in
this section.)
6. Adjust oil level following the procedure below
(Fig. 1 D-3).
Collected Amount
more than 90cc
(3.0 fl.oz.)
Charging Amount
same as collected amount
less than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
7. Install the compressor, then evacuate, charge
and
perform oil return operation.
8. Check system operation.
When it is impossible to perform oil return oper­
ation, the compressor oil should be checked in the
following order:
1. Discharge and recover refrigerant and remove
the compressor.
2. Drain the compressor oil and measure the
extracted oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90cc (3.0 fl.oz.) of oil is extracted
from the compressor, supply same amount of
oil to the compressor to be installed.
If
the amount of oil extracted is less than 90cc
(3.0 fl.oz.),
recheck the compressor oil in the
following order:
5. Supply 90cc (3.0 fl.oz.) of oil to the compressor
and install it onto the vehicle.

1 D-4 COMPRESSOR OVERHAUL
6. Perform oil return operation.
7. Remove the compressor and recheck the
amount of oil.
8. Adjust the compressor oil, if necessary.
Collected Amount
more than 90cc
(3.0
fl.oz.)
Charging Amount
same as collected amount
less than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
Checking and Adjusting for Compressor
Replacement
150cc (5.0 fl.oz.) of oil is charged in compressor
(service parts).
So it is necessary to drain the
proper
amount of oil from the new compressor.
1. Perform oil return operation.
2. Discharge and recover refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the
extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust oil level as required.
Amount of oil drained
from used compressor
less than 90cc
(3.0
fl.oz.)
Draining amount of oil
from new compressor
Same as drained
amount
more than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
6. Evacuate, charge and perform oil return oper­
ation.
7. Check system operation.
CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor
oil. Even if the compressor runs for a
long period
of time (approximately 1 season), the
oil never becomes contaminated as long
as there is
nothing
wrong with the compressor or its method
of use.
Inspect the extracted oil for any of the following
conditions:
• The capacity of the oil has increased.
• The oil has changed color to red.
• Foreign substances, metal powder, etc., are
present in the oil.
If any of these conditions exists, compressor oil
is contaminated. Whenever contaminated com­
pressor
oil is discovered, the receiver/dryer must
be
replaced.
OIL RETURN OPERATION
There is close affinity between the oil and the
refrigerant. During normal operation, part
of the oil
recirculates
with the refrigerant in the system.
When checking the
amount of oil in the system, or
replacing any component of the system, the com­
pressor
must be run in advance for oil return oper­
ation. The procedure is as
follows:
1. Open the all doors and engine hood.
2. Start the engine and air conditioning switch is
"ON" and Set the fan control knob at its hig­
hest position.
3. Run the compressor for more than 20 minutes
between
800 and 1,000 rpm in order to operate
the system.
4. Stop the engine.
REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply
the following
amount of oil to the component parts
to be installed.
Component parts to be installed Amount of oil
Evaporator 50cc
(1.7
fl.oz.)
Condenser 30cc
(1.0 fl.oz.)
Receiver/dryer 30cc
(1.0 fl.oz.)
Refrigerant line (one piece) 1 Occ (0.3 fl. oz.)
Fig. 1 D-3
•

48-12 REAR AXLE
1. Parking brake cable
• Remove the parking brake cable fastening clip
and disconnect the equalizer section. Refer
to
Section SC "PARKING BRAKES".
2. Nut
• Remove the bearing holder fixing nuts.
3. Axle shaft assembly
• Be sure notto damage the oil seal by axle shaft.
4.
Bolt and nut
• Remove differential carrier mounting bolts and
nuts.
5. Differential assembly
1••1 INSTALLATION
5. Differential assembly
• Clean the contact surfaces of the axle and
differential carrier.
• As shown in the drawing, apply Three Bond
TB1215
or equivalent (Fig. 4B-19).
3mm
Fig. 4B-19
4. Bolt and nut
• Tighten the differential carrier mounting bolts
and nuts
to the specified torque.
Torque
N·m (lb·ft) Bolts Nuts
44
(33)
66 (48)
3. Axle shaft assembly
• Be sure notto damage
the oil seal by axle shaft.
2. Nut
• Refer to "AXLE SHAFT' in this section.
1. Parking brake cable
• Refer to Section 5C "PARKING BRAKES".
NOTE:
After completing the assembling work, fill the
prescribed gear
oil to the filler hole.
~·
Lubricant capacity liter (US gal) j 1.8 (0.5)
Tighten the oil filler plug to the specified
torque.
Torque
N·m (lb·ft) 78 (58)

FRONT DRIVING AXLE 4C-37
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
4WD
Axle tube
Type
Gear type
Gear ratio
Differential type
Oil capacity
Axle shaft type
Hub locking
Type (to
1)
liter (US gal)
It consists of the
duct, a cast
iron housing and the axle tube.
Hypoid
4.555
Two pinion
1.5 (0.4)
Constant velocity joint (Birfield joint
type and double offset joint)
Automatic locking
hub

·-------------------------------------
ENGINE (V6 3.2L DOHC AND SOHC) 6A1-63
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Items S pacifications
Engine type,
number of cylinders and Water-cooled, four cycle V6 vertical
arrangement
Form
of combustion chamber
Pent-roof type
Valve mechanism SOHC/DOHC belt drive
Cylinder liner type
Casted in cylinder block
Total
piston displacement
3165 cc
Cylinder bore X stroke 93.4mm X 77mm (3.677in X 3.031 in)
Compression ratio
SOHC: 9.3 DOHC: 9.8
Compression pressure
at
300rpm SOHC: 12.0kg/cm2 DOHC: 12.5kg/cm2
Engine idling speed rpm Non-Adjustable (750)
Valve clearance Non-Adjustable
Oil capacity SOHC: 6.0 liters DOHC:
6.0 liters
Ignition
timing Non-Adjustable (16.BTDC at Idle rpm)
Spark
plug FR2LS, BKR6E-11, K20PR-U11
FR3LS, BKR5E-11 I K16PR-U11
Plug gap 1.0-1.1 mm (0.03937in-0.043307in)

68 - 2 ENGINE COOLING
The cooling system is a pressurized Engine Coolant
(EC) forced circulation type which consists of water
pump, thermostat cooling fan, radiator and other
components. The automatic transmission fluid is
cooled by the EC in radiator.
WATER PUMP
Fig. 68-2
The
EC pump is a centrifugal impeller type and is
driven by timing belt. (Fig.68-2)
THERMOSTAT
Jiggle valve
Fig. 68-3
The
thermostat is a wax pellet type with a jiggle
valve and is installed in the thermostat housing.
(Fig.68-3)
RADIATOR
The radiator is a tube type with corrugated fins. In
order to raise the boiling point of coolant, the radiator
is fitted
with a cap in which the valve is operated at
88.2
-117.6 kPa (12.8 - 17.0 psi) pressure. (No oil
cooler
provided for M!f)
Fig. 68-4
ANTI-FREEZE SOLUTION
•
•
Relation between Mixing ratio and Freezing
temperature
of the EC varies with the ratio of
anti-freeze solution in water. Proper mixing
ratio can be determined by referring to the
chart. Supplemental inhibitors or additives
claiming to increase cooling capability that have
not been specifically approved by lsuzu are not
recommended for addition to the cooling
system.
Calculation mixing ratio (Fig. 68-5)
Mixing ratio
Anti-freese
solution (Lit/gal.) =-----------------Anti-freese solution (Lit/gal.) +Water (Lit/gal.)
Note: Anti-freeze solution +Water=
Total cooling system capacity.
Lit (Us
gal)
Total Cooling
M!f 8.5 (2.24) ~-~~--------System Capacity AfT 8.8 (2.32)

Mixing ratio(%) 0 10 20 30 40 50
~
' -10
'
1
' -30

~ -40
In case of 8.5 lit total cooling system capacity
Mixing Anti-freeze
Water: solution: ratio (%) lit. (U.S. gal) lit. (U.S. gal.)
0 0 0
8.5 (2.2) 10 0.9 (0.3) 7.6 (2.0) 15
1.3 (0.4) 7.2 (1.9) 20 1.7 (0.5) 6.8 (1.8)
25 2.1 (0.6) 6.4 (1.7) 30 2.6 (0.7) 5.9 (1.6)
35 3.0 (0.8) 5.5
(1.5) 40 3.4 (0.9) 5.1 (1.3)
45 3.8 (1.0) 4.7 (1.2) 50 4.3 (1.1)
4.2 (1.1)
Fig. 68-5
ENGINE COOLING 68-3
• Mixing ratio
Check
the specific gravity of engine coolant in the
cooling system temperature ranges from oo C to
50° C using a suction type hydrometer, then deter­
mine the densityofthe Engine Coolant by referring
to the table. (Fig. 68-6)
1,100 1'-........ ........ ...... .............. Mixing ratio
~"""--r-... 1'-""' 1,1)90
........ ...... ........ ........ .......... '
1,000
'"" 1,07 o......_ 1'-........ I'-.......... I"-........ .......
I"-........ ..........
................. I"-........
'
1,080
....... I"-........ ~ ........ ......
........ "'" ~"""--r--..... 1,050
r-. ........ ~ .......... ......
---
........ ........ 1,040
r-.... !'--.. 1'-0 '"" ~"""--1'-.... ........ 1,03
1--....... ........ r--~ ........
'
1,020
....... ~ 1'-0 ~"""---.... 1,01
...... ,
'
1,000
10 20 30 40 50 60 70 Coolant temperature ("C)
Fig. 68-6
DIAGNOSIS
ENGINE COOLING TROUBLE
Condition Possible cause Correction
Engine
overheating Low Engine Coolant level Replenish
Thermo unit faulty Replace
Faulty
thermostat Replace
Faulty
Engine Coolant unit Repair or replace
Clogged
radiator Clean or replace
Faulty
radiator cap Replace
Low engine oil level or use of improper Replenish or change oil
engine oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position sensor circuit Repair or replace
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to Faulty thermostat Replace
warm-up Thermo unit faulty Replace

DRIVEABILITV AND EMISSIONS 6E2-165
DIAGNOSIS
FUNCTIONAL CHECK OF POSITIVE
CRANKCASE VENTILATION (PCV)
If an engine is idling rough, check for a clogged PCV or
plugged hose. Replace as required. Use the following
procedure.
1. Remove PCV from rocker arm cover.
2. Run the engine at idle.
3. If there is no vacuum at valve, check for plugged
hoses or manifold port, or PCV.
Replace plugged or deteriorated hoses.
4. Stop the engine and remove PCV. Remove
PCV hose. Inspect metered orifice for being
restricted or
plugged. If restricted clean orifice.
With this system, any
blow-by in excess of the system
capacity (from a
badly-worn engine, sustained heavy
load, etc.) is exhausted into the intake manifold and is
drawn into the engine. Proper
operation
of the PCV System is dependent
upon a
sealed engine. If oil sledging or dilution is
noted, and the PCV System is functioning properly,
malfunction
indicator lamp for possible cause and
correct to ensure that system
will function as intended.
RESULTS OF INCORRECT OPERATION
A plugged valve or hose may cause:
• Rough idle.
• Stalling
or slow idle speed.
• Oil leaks.
• Oil
in air cleaner.
• Sludge
in engine.
ON-VEHICLE SERVICE
An engine which is operated without any crankcase
ventilation can be damaged. Periodically, inspect the
PCV, hoses
and clamps and replace any showing
signs
of deterioration.

MANUAL TRANSMISSION 78-39
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Transmission type
Transfer case
Control method
Gear ratio: Transmission
1st
2nd
3rd
4th
5th
Rev.
:Transfer High
low
Transmission oil capacity lit. (US qt)
Transfer
oil capacity lit. (US qt)
Type
of lubricant Fully
synchronized
5-forward gears
Constant mesh type gears shifting between the
2
and 4 wheel drive mode. Synchronized type gears
between
"low" and "high"
Remote control with the gear shift lever on the floor.
3.767
2.248
1.404
1.000
0.809
3.873
1.000
2.283
2.95
(3.12)
1.45 (1.53)
Engine oil
Refer to chart in Section 0

TRANSFER CASE 70-29
1. Bearing snap ring
Fig. 70-79
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Type Constant mesh type gears shifting between the 2 and 4
wheel drive mode.
Synchronized type gear
(M/T only) between "low" and
"high".
Control method Direct control with the gear shift lever on the floor.
Gear ratio
High; 1.000
Low; 2.283
Oil capacity lit. (U.S. quart) 1.45 (1.53)
Type of lubricant Engine oil
Refer to chart in Section
0