ECO mode ISUZU TROOPER 1998 Service Repair Manual

MAINTENANCE AND LUBRICATION 0BÐ7
RECOMMENDED FLUIDS, LUBRICANTS
AND FUELS
In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very
important to select and use correctly best lubricants and diesel fuels.
When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below,
according to the maintenance schedule for each vehicle model.
The lubrication intervals in the maintenance schedule and the coverage and period of new vehicle warranty
are based on the use of ISUZU genuine lubricants or recommended lubricants as given in the chart which
will serve as a guide for selecting lubricants of proper brand name.
LUBRICATION MAKE BRAND / TYPEGRADE
API ACEA
ISUZU GENUINE BESCO MULTI Ð Z TYPE CE (10W-30) CE
ISUZU GENUINE BESCO MULTI Ð Z (10W-30) CD
ISUZU GENUINE BESCO MULTI Ð Z SUV (5W-30) CD
ISUZU GENUINE BESCO S Ð 3 (10W, 20W, 30, 40) CD
Diesel engine crankcase EXXON / ESSO ESSOLUBE XD-3+ (15W-40) CG4/CF E2/B2
EXXON / ESSO ESSOLUBE XT331 (15W-40) CG-4/CF E2/B2
MOBIL DELVAC HP (15W-40, 20, 30, 40) CF/CE
CALTEX / CHEVRONDELO CXJ (15W-40, 30, 40) CF
SHELL RIMURA D (15W-40, 30, 40 CD/CF
ELF PERFORMANCE TROPHY (15W-40) CE E3
TOTAL RUBIA XT (15W-40) CF-4 E2
ISUZU GENUINE BESCO RACING ACE (7.5W-30) SG
ISUZU GENUINE BESCO MULTI ACE (7.5W-30) SF
ISUZU GENUINE BESCO ACE (10W-30) SE
EXXON / ESSO ESSO SUPERFLO (15W-40, 15W-50, 20W-50) SJ A2
Gasoline engine EXXON / ESSO ESSO UNIFLO (15W-40, 15W-50, 20W-50) SJ A2
crankcase MOBIL MOBIL SUPER XHP
(15W-40, 15W-50, 20W-50)SJ A3
CALTEX / TEXACOHAVOLINE FORMULA-3 (15W-40, 20W-50) SJ
SHELL HELIX SUPER (10W-30) SJ
ELF SUPER SPORTI S (15W-40) SG
TOTAL QUARTZ 5000 (15W-40, 20W-50) SJ A2
ISUZU GENUINE BESCO GEAR OIL TRANSAXLE (5W-30) SG
EXXON / ESSO ESSOLUBE XD-3+ (15W-40) CG-4/CF E2/B2
EXXON / ESSO ESSOLUBE XT331 (15W-40) CG-4/CF E2/B2
Manual transmission MOBIL MOBIL SUPER (10W-30) SH
Transfer caseCALTEX / TEXACOHAVOLINE FORMULA-3 (15W-40, 20W-50) SH
SHELL RIMURA D (15W-40) CD/CF
ELF SUPER SPORTI S (15W-40) SG/CD
TOTAL QUARTZ 5000 (15W-40, 20W-50) SJ/CF A2/B2
ISUZU GENUINE BESCO GEAR OIL SH (80W-90, 90, 140) GL-5
ISUZU GENUINE BESCO SHIFT ON THE FLY (75W-90) GL-5
DifferentialEXXON / ESSO GEAR OIL GX (85W-90) GL-5
Shift on the fly systemMOBIL MOBILUBE HD (80W-90, 85W-140) GL-5
(GL-5 only)CALTEX THURBAN GL-5 EP (80W-90, 85W-140) GL-5
SHELL SPIRAX HD (90, 140) GL-5
ELF TRANSELF TYPE B (80W-90, 85W-140) GL-5
TOTAL TRANSMISSION TM (80W-90, 85W-140) GL-5
ISUZU GENUINE BESCO GEAR OIL LSD (140) GL-5
EXXON / ESSO GEAR OIL LSA (90) GL-5
Differential MOBIL MOBILUBE HD LS (80W-90) GL-5
(Limited Slip Differential) CALTEX GEAR OIL LSD (90) GL-5
ELF TRANSELF TYPE BLS (90) GL-5
TOTAL TRANSMISSION DA (85W-90) GL-5

00 Ð 52 SERVICE INFORMATION
HFC-134a
SPECIAL TOOLS
ILLUSTRATION PARTS NO. PARTS NAME
5-8840-0629-0
ACR
4(115V 60Hz)
(J-39500-A)
5-8840-0630-0
ACR
4(220-240V 50/60Hz)
(J-39500-220A)
5-8840-0631-0 ACR
4(220-240V 50/60Hz
(J-39500-220ANZ) Australian model)
ACR
4: HFC-134a Refrigerant Recovery / Recycling
/Recharging / System

AIR CONDITIONING 1B Ð 13
ACR41) Using the ACR4(HFC-134a Refrigerant Recovery/
Recycling/ Recharging/ System) or equivalent to
thoroughly discharge and recover the refrigerant.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
2) Remove and replace the defective part.
3) After evacuation, charge the air conditioning
system and check for leaks.
PRECAUTIONS FOR REPLACEMENT OR REPAIR OF
AIR CONDITIONING PARTS
There are certain procedure, practices and precautions
that should be followed when servicing air conditioning
systems:
·Keep your work area clean.
·Always wear safety goggle and protective gloves
when working on refrigerant systems.
·Beware of the danger of carbon monoxide fumes
caused by running the engine.
·Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
·Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
·When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
·Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or
parts are reconnected or installed.
·When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
·Always install new O-rings whenever a connection is
disassembled.
·Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
·When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
ON-VEHICLE SERVICE

1B Ð 14 AIR CONDITIONING
REPAIR OF REFRIGERANT LEAKS
Refrigerant Line Connections
Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the
connecting portion from twisting or becoming damaged.
When connecting the refrigerant line at the block joint,
securely insert the projecting portion of the joint portion
into the connecting hole on the unit side and secure with a
bolt.O-ring
Block joint
Apply specified compressor oil to the O-rings prior to
connecting.
CAUTION:
Compressor (PAG) oil to be used varies according to
compressor model. Be sure to apply oil specified for the
model of compressor.
O-rings must be closely aligned with raised portion of
refrigerant line.
Correct Incorrect Incorrect
 

1B Ð 16 AIR CONDITIONING
WARNING
·SHOULD HFC-134a CONTACT YOUR EYE(S),
CONSULT A DOCTOR IMMEDIATELY.
·DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER
OVER THE AFFECTED AREA TO GRADUALLY
RAISE THE TEMPERATURE OF THE
REFRIGERANT ABOVE THE FREEZING POINT.
·OBTAIN PROPER MEDICAL TREATMENT AS
SOON AS POSSIBLE. SHOULD THE HFC-134a
TOUCH THE SKIN, THE INJURY MUST BE
TREATED THE SAME AS SKIN WHICH HAS
BEEN FROSTBITTEN OR FROZEN.
REFRIGERANT RECOVERY
The refrigerant must be discharged and recovered by
using ACR4(HFC-134a Refrigerant Recovery/ Recycling/
Recharging/ System) or equivalent before removing or
mounting air conditioning parts.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
1) Connect the high and low charging hoses of the ACR
4
(or equivalent) as shown
2) Recover the refrigerant by following the ACR4
ManufactureÕs Instructions.
3) When a part is removed, put a cap or a plug on the
connecting portion so that dust, dirt or moisture
cannot get into it.
ACR4
(Low side) (High side)
HFC 134a
REFRIGERANT RECYCLING
Recycle the refrigerant recovered by ACR4or equivalent.
For the details of the actual operation, follow the steps in
the ACR
4ManufactureÕs Instructions.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)

1B Ð 18 AIR CONDITIONING
CHARGING THE REFRIGERANT SYSTEM
There are various methods of charging refrigerant into the
air conditioning system.
These include using ACR
4(HFC-134a Refrigerant
Recovery/ Recycling/ Recharging/ System) or equivalent
and direct charging with a manifold gauge charging
station.
ACR
4(115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4(220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4(220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
Charging procedure
·ACR4(or equivalent) method
For the charging of refrigerant recovery by ACR4, follow
the manufactureÕs instruction.
ACR4
(Low side) (High side)
HFC 134a

AIR CONDITIONING 1BÐ89
2. Air Flow Control
¥ In the Auto Mode
The automatic heater/air conditioner control unit
operates on the setup temperature signal and
other sensor signals to derive the total signal.
Then, the control unit adjusts base potential of
the power transistor to match it to the voltage
pattern of the target fan so that stage-less fan
speed control can be achieved.
When solar radiation quantity is detected in the
VENT or B/L mode, the control unit increases the
minimum fan voltage to offset.
When FH or FC is selected from the temperature
control switch, air flow is accordingly fixed to
MAX HI or AUTO HI.
¥ In the Manual Mode
Air flow specified from the fan switch is entered
to the automatic heater/air conditioner control
unit as the manual signal. The signal modifies
the air flow to the level specified from the fan
switch so that the required fan voltage is
attained.3. Mode (Blow Port) Control
The automatic heater/air conditioner control unit
operates on the setup temperature from the
control switch, and temperature and solar
radiation quantify from the sensors to determine
the total mode control signal. According to the
pattern specified by this signal, the control unit
selects either one of the VENT, BI-LEVEL, FOOT
or DEF/FOOT mode.
The mode actuator determines the rotation
direction comparing the target position against
the current position being determined by the
position detection signal.
When FH or FC is selected for the temperature
from the temperature control switch, mode is
accordingly fixed to the VENT or FOOT.
¥ In the manual operation of the mode switch, you
can select a desired blow port mode pressing
the corresponding mode switch.
¥ Operating the DEF mode switch selects the DEF
for the blow port mode.
4.512
(V)
M
MAX
HI Relay
Power
transistor
4.8 10.5MAX HI Set up
temperature signal
Control unit
In car sensor
Ambient sensor
Sun sensor
Mode control
signal Fan switch
AUTO HI
Heater
sideCooler
side Total signalVENT mode
Blower fan motor terminal voltage
C01RY00008
Mode control
DEF / FOOTSet up temperature
signal
Mode actuator
Mode doorPosition
detection
switch
Control unit
In car sensor
Sun sensor
Air conditioning
switch
Mode control
signal Ambient sensor
FOOT
BI-LEVEL
VENT
Heater
sideCooler
side Mode total signal
C01RY00009

1BÐ90 AIR CONDITIONING
4. Intake (Fresh air/interior air switching) Control
In the Full Auto mode, the automatic heater/air
conditioner control unit operates on the setup
temperature signal and other sensor input
signals to derive the total signal. According to
the pattern specified by this signal, the control
unit provides the intake control.
When the fan is turned off or the A/C (air
conditioning) is turned off, the intake is fixed to
the FRESH mode.
When FC or FH is selected from the control
switch, the intake mode is accordingly fixed to
the RECIRC or FRESH.
¥ In the Manual Operation
Pressing the FRESH (fresh air intake) or the
RECIRC (room air circulation) accordingly selects
the FRESH or RECIRC mode.
¥ When the DEF Mode Switch is depressed
The intake mode is fixed to the FRESH. When
the MANU REC is selected, however, the mode
is fixed the RECIRC.
¥ When the Mode Switch is depressed
If the automatic intake control is selected, the
intake is fixed to the currently selected mode.5. Compressor Control
In the automatic control mode, the automatic
heater/air conditioner control unit turns on or off
the compressor with the evaporator anti-freeze
mechanism using the duct sensor. And, when
outside air is detected to be low through the
ambient sensor signal, the control unit turns off
the compressor using the compressor control
function.
¥ Manual Control
In the automatic control mode, pressing the A/C
(air conditioning) switch turns off the
compressor.
¥ Pressing the DEF mode switch automatically
turns on the compressor.
Intake door open / close
RECIRC Setup temperature
signal
Intake
actuator
Position
detection
switch
In car sensor
Ambient sensor
Sun sensor
Compressor
ON / OFF
Fan ON / OFF
Intake switch
Control unit
Intake door
MIX
FRESH
Heater
sideCooler
side Total mode signal
C01RY00012
Ambient sensor
Control unit
Pressure switch
Thermo switch relay
ECM
Compressor relay
Compressor
Electronic
thermostat
Air conditioning
switch
Set up temperature
signal
C01RY00010

AIR CONDITIONING 1BÐ91
6. Heating Start Timing Control
When the automatic heater/air conditioner is
started, heating is turned on under following
conditions.
·The detected temperature of thermo unit is
136¡F or less.
·The temperature setting signal and the total
signal by each sensor meet the condition of
heating.
When the detected temperature by the coolant
temperature sensor is 136¡F or less the blower
fan motor is set to work at low speed and the
"DEF" mode is selected.
When the detected temperature by the coolant
temperature sensor is 77¡F or more, the blow
mode changes automatic control. And the
blower fan speed is controlled to be lineally up
from "LO" to "MAX HI".7. Cooling Start Timing Control
When the automatic heater/air conditioner is
started, cooling is turned on under following
conditions.
·The in car sensor is 86¡F or more.
·The temperature setting signal and the signals
from each sensor meet the specified condition.
The blower fan speed is set to "LO" for
maximum 7 seconds when cooling start
conditions meet, and then, is controlled to be
lineally up to "MAX HI" by 5.32%/S.
Ignition swich
"ON"
Time
Blower voltage to turn
on the cooling
7 SEC maximum3 SEC
100%
(MAX HI)
33.5%
(LO)5.32%/S
C06RY00001
33.5%
(LO)
2.63%/S
Mode
DEF
Auto
Mode
100%
(MAX HI)
Ignition
switch "ON"
Thermo Unit 58¡C(Gasoline)
52¡C(Diesel) Time
840RY00009

1BÐ96 AIR CONDITIONING
Checking ApproachNo.ItemAcceptance criteria
Condition Operation
Change the
temperature gradually
starting with 20¡C up to
30¡C.The following phenomena shall be
recognized.
¥ Temperature of blown air: Cold
air is changed to hot air.
¥ Change in the air flow volume.
¥ The blow port mode LED
indication changes in the
following sequence:
Select FH for the
temperature.Cold air shall be blown out.
The following LEDs shall come on.
¥ Blow port mode :
¥ Fan speed: Max Hi Select FC for the
temperature.The LED shall come on.
Cold air shall be blown out.
The following LEDs shall come on:
¥ Blow port mode :
¥ Intake mode
¥ Fan speed : MAX Hi
¥ A/C
1 Full Auto function FAN KNOB ÒAUTOÓ
MODE SW ÒAUTOÓ
2. Check of Full Auto Function
(VENT) (FOOT)(BI-LEVEL)
F01RX003 F01RX002
F01RX004