towing ISUZU TROOPER 1995 Workshop Manual

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)

ENGINE DIAGNOSIS 6-13
ENGINE OIL CONSUMPTION EXCESSIVE
Condition Possible cause Correction
Oil leaking
Oil pan drain plug loose Retighten or replace gasket
Oil pan setting bolts loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining
bolts loose or Retighten or replace gasket
gasket broken
Head cover retaining
bolts loose or Retighten or replace gasket
gasket broken
Oil cooler adapter cracked Replace
Oil cooler
center bolt loose Retighten
Oil cooler 0-ring broken Replace
Oil cooler
piping loose or broken Retighten or replace
Oil filter
adapter cracked Replace
Oil filter
attachings bolt loose or rubber Retighten or replace oil filter
gasket broken
Oil cooler broken Replace
Crankshaft front or rear oil seal Replace oil seal
defective
Oil pressure unit loose or broken Retighten or replace
Blow-by
gas hose broken Replace hose
Positive Crankcase Ventilation
Valve
Clean
clogged
Engine/Transmisison coupling area Replace oil seal
Oil leaking
into combustion Valve stem oil seal defective Replace
chambers due to poor seal in Valve stem or valve guide worn Replace valve and valve guide valve system
Oil leaking into combustion
Cylinders and pistons worn excessively Rebore cylinder and replace
chambers
due to poor seal in pistons and others
cylinder parts
Piston ring gaps incorrectly positioned
Correct
Piston rings set
with wrong side up
Correct
Piston ring sticking Rebore
cylinder and replace
pistons and others
Piston rings and ring grooves
worn Replace pistons and others
Return ports in
oil rings clogged Clean piston
and replace rings
Crank case ventilation, Positive
Positive Crankcase Ventilation
Valve Clean
Crankcase Ventilation System clogged
malfunctioning
Others Improper oil viscosity
Use oil of recommended
S.A.E. viscosity
Continuous high speed driving
and/or Continuous high speed
servere usage such
as trailer towing operation and/or severe usage
will normally cause increased
oil consumption

7A-16 AUTOMATIC TRANSMISSION (4L30-E)
DRIVER INFORMATION
To analyze the problem fill a complete description of the owner's complaint.
Please draw a circle around the right information and complete the following form. (Find next page an
example of form completed). You can draw a circle around many numbers if you are not sure.
A-Today' a date : Month: ............... Day:·············· Year: ...............
B-Ead User Name, Address :
C-Dat~ of Problem : Month: ..................... Day: ................. Year: ................
D-Mileaae: E-With Ignirioa. ON ia OIECK F -Car load wheo proHem oceand :
...............
Miles/Km TRANS lodicator : 1 - Towing a trailer 2-.......... people OR ......... Kg
1-Flashing 2-Not Flashing
G-Weather coa.ditiou whea. H-Weather Temperature whea I -Road Cooditioaa wheu problem J-Frequeucy ofthe Problem :
!Problem: problem: : 1-Always 2-Occuional :
1-Clear 2-Cloudy 1-Hot 2-Warm 1-Any 2-Inter City ........ times/day,
3-
Rain 4-Snow 3-Cool 4-Cold 3-Outsid~ City 4- Highway douooo times/month
5- Unstable
6-Any 5-Unstable 6- Any S-Uphill 6-Downhill 3-
Only Once 4-Otheu:
7-Unpaved 8-Snow
9-Others:
IK-EJI&iae Coaditioa : L-Eagiae Spttd whca the problem M-Traasmissiou Coa.diriou wbea
1-Always 2- At Cold occand: it occund:
3-During Warming up 1-Idling 2-Starting 1-Any 2-
Idling
4-After Warming or Hot 3-Stalling 4-HighRPM 3-Starting 4-Driving
5-Others 5-LowRPM 5-Accelerating 6-Coasting
7-Inc:omer 8-Shifting
N-If then b a Trauamiuioa drivcabillty problem BEFORE TIIE CHECK TRANS
INDICATOR WAS FI..ASHING :
I-No Power in Range: All-P-R-N-D-3 -1-L during
a : upshift : 1-2 I 2-3 I 3~4 or downshift : 4-3 I 3-2 I 2-1
2-No shift in Range :All-P-R-N-D-3-2-L during a: upshift
: 1-2 I 2-3 I 3-4 or downshit : 4-3 I 3-2 I 2-1
3- Shift Shock in Range: All-P-R-N-D -3-2-L during a
:upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
4-Shift Slip in Range: Ali-P-R-N -D-3 -2 -L during a: upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
5-Shift Delayed in Range : All -P -R-N - D - 3 - 2 - L during a: upshift :
1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
6-Shi1 Point too high in Range :All -P-R-N-D-3-2. L during a: upshift:
1-2 I 2-3 I 3-4 or downshift: 4-3 I 3-2 I 2-1
7-Shift Point too low
in Range : All -P -R-N-D-3 -2-L during
a : upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
S-TCC Shudder in Range :All-P-R. N-D-3-2-L during a: upshift
: 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
9-Noise in Range : All -P -R-N - D - 3 - 2 - L during a: upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
INolae type: 1-Buzz 2-Whine 3-Clunk 4-Rattle S-Whistle II 6-light 7-medium 8-hoavy
10-Other: ..................... in Range : All -P -R-N - D - 3 - 2 - L during a: upshit :
1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
0-Other cDitomer co aura. aad commeats
P •
bUZD Vebiele Code : ooo,0ooooooooooou• .. ouooooooooooooo•••••o•U Q-VIN Number ··················\
··················\
··········
R-Date orVebiclc Regjatratiou Month: ..................... Day: .............. Year: ...............
S • Traua. model: .................... -. ......................... T-Aff Serial Number : uo••••••••••••••••••\
•••oo•oooooooooooooouooo
U-Your aame: ··················\
··················\
··········
y. Dealer Naau, Addn .. , Pbou~
•

AUTOMATIC TRANSMISSION (4L30-E) 7A-17
Example of form completed.
A-Today's date : Month : April .............. Day: .13 ............. YOM: .1994 ..............
B-Ead U.er Name, Address : Dave Smith
6584, Arlington road
P1ymoutll Ml 48170
USA
C-Date or Problem :
Month : April... ................ Day:.8 ................ You : .1994 ...............
D-Mileace: E-With lguirioa ON is CHECK F -Car load whcu problem occartd:
12230 .. J.@1Km @! TRANS ludicator: 1 -Towing a trailer 2-.. 2 ....... people OR ......... Kg ashing 2-
Not Flashing
G-Weatbtr couditious wbeu H-Weather Temperature wheu I-Road Conditions ""hen problem J-Frequency or the Problem : problem: problem: : 1-Always ~sionaJ :
1-Clear 2- Cloudy 1-Hot 2-Wann 1-Any l.-lltto:r City ........ fio•~s/ y,
3-
Rain 4-Snow 3-Cool ~d 3-Owside City (j}Highway .. .3 ... tim~stmonth 5-Unstable (!).ny S-Unstable 6- y 5-Uphill ti-Downhill 3-Only Once 4-Otb.n: 7-Unpaved )8t.now 9-Others .......___
l!Jis 111P.
K -Euciue Coa.dition : L-Engiue Speed wbea the problem M-Traasmiuioo Condition wheu ~e IJJis 7~~· do l1ot
!-Always 2-At Cold occared: it occared: lJto a
~ing Warming up 1-Idling 2-Starting 1-Any 2-Idling C'collnt
er Warming
or Hot 3-Stalling (3Higt~RPM 3-Starting 4-Driving
5-Others S-Low RPM (~cceleratin~~~~g 7-lr. comer 8-JUftmg
IN-Irtbcrt is a Transmission drive ability problem BEFORE THE CHECK TRANS INVJCATOR WAS FLASHING :
1-NoPower in Range : All -P -R-N-D-3 - 2 - L during a: upshift: 1-2 I 2-3 J 3-4 or downshift: 4-3 I 3-2 / 2-1
~hift inR.ange:AII-P-R-~-0-3-2-L during a : up~hifl : 1-2 I 2-3 ! 3-4 01 uowushifl : ~-3 I 3-2 I 2-1 Shock in Range: AII-P-R-N -~ -2-L during·~-: I 2-3 I (Do~:Qi 3-2 I 2-l 4-Shift Slip in Range : All -P -R-N - D - 3 - 2 - L during a: ups "ft : 1-2 I 2-3 / 3-4 or dov.nshift : 4-3 / 3-2 I 2-1
S-Shift Delayed
in Range,.: All -P -R-N -D-3 -2 - L during
a :upshift : 1-2 I 2-3 I 3-4 or dovmshift : 4-3 I 3-2 I 2-1
6-Shift Point too higJl in Range :All -P-R-N • D-3-2-J.. during a : upshift : 1-2 I 2-3 ! 3-4 or downshift : 4-3 I 3-2 I 2-1 7-Shift Point too low
in Range :All -P-R-N-D-3-2; L during a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
8-TCC Shudder
in Range : All -P - R
- N - D - 3 -2 - L during
a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
9-Noise in Range : All -P -R-N -D-3 -2-L during a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
~oise type: 1-Buzz 2-Whine 3-Clunk 4-lWtle S-Whistle II 6-light 7-medium 8-heavy
10-0thor: ..................... inR.ange:AII-P-R-N-0-3-2-L during
a :upshift : 1-2 I 2-3 I 3-4 or downshift : 4-3 I 3-2 I 2-1
0-Other customer co accra aa.d com meat• :
(This is just an e~ample ). Shift shock very harsh
overall during a downshift. Not sure if
it's the 4-3 or 3-2.
P-huza Vehicle Code : 94 UCR Q -VIN Number 4S2CV58ZXM432404 7
R-Date ofVehieJe Re~stratioa Month : .November. Day: ... .18 ........ Year: . .1993 .........
S -Traaa.. mtldel : 4L30-E T-Aff Serial Number : 96 358 654
U-Yoali'D.ame: Joe Spring
V-Dealer Name, Address, Phooe
Kent Helfrich
Home-town ISUZU
900 -999 -9999

7 A-20 AUTOMATIC TRANSMISSION (4L30-E)
CHECKING TRANSMISSION FLUID
LEVEL AND CONDITION
Checking fluid level and condition (color and odor)
at
regular intervals will provide early diagnosis
information about the transmission. This inform­
ation may be used to correct a condition that, if not
detected early, could result in major transmission
repairs.
IMPORTANT: When new, automatic transmission
fluid is red in color. As the vehicle is driven, the
transmission
fluid will begin to look darker in color.
The
color may eventually appear light brown.
A DARK
brown color with burnt odor may indicate
excessive
fluid deterioration and signal a need for
fluid change.
FLUID LEVEL
When adding
or changing fluid, use only DEXRON
®-Ill.
Refer to the Maintenance and Lubrication (Section 0
of this manual) for maintenance information and
servicing
interval.
\f CAUTION: DO NOT OVERFILL
Overfilling will cause foaming, loss ~f fluid,
abnormal shifting and possible damage to
the transmission.
1. Start engine and drive vehicle until normal AfT
oil operating temperature is reached:
NOTE: The automatic transmission fluid level
must be checked with the vehicle at normal
A/T oil operating temperature: 75 TO 85°C
(167 TO 185°F) MEASURED WITH TECH1 SCAN
TOOL.
Temperature will greatly affect transmission
fluid level.
If the vehicle is not at normal AfT oil operating
temperature and the proper checking
procedures are
not followed, the result could
be a false reading of the fluid level indicator
and
an incorrect adjustment of the fluid level.
2. Park vehicle on level ground.
3. Move gear selector to "Park".
4. Apply parking brake and block wheels.
5. Allow vehicle to idle for 3 minutes with all
accessories turned off.
6. Check fluid level with engine running at idle:
Fluid should
be in "HOT" area on AfT dipstick
(Fig. 7A-6).
Check also color and condition (Refer to next
page.)
Hot
Cold ---IIU 0
0
Min
Dipstick
Fig. 7A-6
\f CAUTION:
DO NOT CHECK FLUID LEVEL UNDER THESE
CONDITIONS: •
At high ambient temperature above 30°C
(86°F).
Immediately after driving at sustained highway
speeds.
• In heavy city traffic during hot weather.
If vehicle is towing a trailer.
If the vehicle has been operated under these
conditions,
shut the engine off and allow the
vehicle to "cool" for thirty (30) minutes. After the
cool-down period, restart the vehicle and continue
from step 2 above.
'~I
......

... ......,.
AUTOMATIC TRANSMISSION (4L30-E) 7A-155
ON-VEHICLE SERVICE
CHECKING TRANSMISSION FLUID
LEVEL
1. Park the vehicle on level ground.
2. Apply the parking brake.
3. Place the automatic transmission in "Park" and
start the engine.
Allow the engine to idle for
two minutes.
4. With the brakes applied, move the shifter lever
through all the gear ranges, ending in "Park".
5. Remove the dipstick, Carefully touch the
dipstick with your finger to determine the
temperature of the fluid. (Fig. 7A-14)
• If the fluid is cool or warm (approximately
room temperature) or slightly higher (but
not too hot to touch), the fluid level should
be within the "Cold" range.
• If the fluid is hot, the fluid level should be
(A; within the "Hot" range.
6.
Cold Hot
Fig. 7A-14
• If the vehicle has just been driven for a long
period of time at highway speeds or in city
traffic in hot weather, wait 30 minutes for
the fluid to cool down before checking fluid
level.
If fluid level is low, add enough DEXRON®-m
Automatic transmission fluid to bring trans­
mission
to its proper fluid level through the
transmission oil filler tube.
NOTE:
The automatic transmission fluid level must be
checked
with the vehicle at normal AfT oil
operating temperature: 75 TO 85°C (167 TO
185°F)
measured with TECH1 scan tool.
Overfilling or underfilling could result in
damage
to the transmission.
• If fluid level is low, inspect the area around
the oil pan for leakage.
•
If the fluid smells burnt or is black, replace
it.
CHANGING TRANSMISSION FLUID
There is no need to change the transmission fluid
unless the transmission is used under one or more
of the following heavy duty conditions.
A: Repeated
short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Towing a trailer
If the vehicle is used under these conditions,
change the fluid every 20,000 miles (32,000 km.)
There is
no drain plug in the oil pan. Oil should be
extracted
with suitable suction device through the
filler tube. Alternately the fluid can be drained by
carefully removing the oil pan. Place a large drain
pan
under the oil pan, remove 13 bolts on the right,
left and front sides of the oil pan and loosen 3 bolts
on the rear side.
Drain
the fluid carefully.
Hold
the pan horizontally, remove the remaining 3
bolts and remove pan and gasket. Clean the oil pan
and
reinstall it . with a new gasket. It is also
recommended to replace the fixing bolts. Tighten
16 fixing bolts to 11 N·m (8 lb·ft.) torque.
MANUAL LINKAGE
~ INSPECTION
1. Make sure that when the shifter control lever is
shifted
from "P" to "L", a "clicking" can be felt
at each shift position. Make sure that the gear
corresponds
to that of the position plate
indicator.
2. Check to see if the shifter lever can be shifted
as
shown in Fig. 7A-15. jQ
~ Button must be pressed.
~ Button need not be pressed.
Fig. 7A-15