engine coolant ISUZU TROOPER 1998 Service Repair Manual

ABBREVIATIONS CHARTS
LIST OF AUTOMOTIVE ABBREVIATIONS WHICH MAY BE USED IN THIS MANUAL
A Ð Ampere(s)
ABS Ð Antilock Brake System
A/C Ð Air Conditioning
ACCEL Ð Accelerator
ACC Ð Accessary
Adj Ð Adjust
A/F Ð Air Fuel Ratio
AIR Ð Air Injection Reaction System
ALDL Ð Assembly Line Diagnostic Link
Alt Ð Altitude
AMP Ð Ampere(s)
ANT Ð Antenna
APS Ð Absolute Pressure Sensor
ASM Ð Assembly
A/T Ð Automatic Transmission/Transaxle
ATDC Ð After Top Dead Center
Auth Ð Authority
Auto Ð Automatic
BARO Ð Barometic
Bat Ð Battery
Bat+ Ð Battery Positive Terminal
Bbl Ð Barrel
BCM Ð Body Control Module
BHP Ð Brake Horsepower
BP Ð Back Pressure
BTDC Ð Before Top Dead Center
¡C ÐDegrees Celsius
Cat. Conv. Ð Catalytic Converter
cc Ð Cubic Centimeter
CCC Ð Computer Command Control
CCOT Ð Cycling Clutch Orifice Tube
CCP Ð Controlled Canister Purge
CID Ð Cubic Inch Displacement
CL Ð Closed Loop
CLCC Ð Closed Loop Carburetor Control
CO Ð Carbon Monoxide
Coax Ð Coaxial
Conn Ð Connector
Conv Ð Converter
CP Ð Canister Purge
CPS Ð Central Power Supply
Crank Ð Crankshaft
CTS Ð Coolant Temperature Sensor
Cu.In. Ð Cubic Inch
CV Ð Constant Velocity
Cyl Ð Cylinder(s)
C
3I Ð Computer Controlled Coil Ignition
DBM Ð Dual Bed Monolith
Diff Ð Differential
DIS Ð Direct Ignition System
Dist ÐDistributor
DOHC Ð Double Overhead Camshaft
DVM Ð Digital Voltmeter (10 meg.)
DVOM Ð Digital Volt Ohmmeter
DVDV Ð Differential Vacuum Delay Valve
EAC ÐElectric Air Control
EAS Ð Electric Air Switching
EBCM Ð Electronic Brake Control Module
ECC Ð Electronic Climate Control
ECM Ð Electronic Control Module
ECU Ð Electronic Control Unit
Ð Engine Calibration Unit (PROM)
EECS Ð Evaporative Emission Control System
EFE Ð Early Fuel Evaporation
EFI Ð Electronic Fuel Injection
EGR Ð Exhaust Gas Recirculation
EGR/TVS Ð Exhaust Gas Recirculation/Thermostatic
Vacuum Switch
ELC Ð Electronic Level Control
ESC Ð Electronic Spark Control
EST Ð Electronic Spark Control
ETR Ð Electronically Tuned Receiver
EVRV Ð Electronic Vacuum Regulator Valve (EGR)
Exh Ð Exhaust
¡F Ð Degrees Fahrenheit
FF Ð Front Drive Front Engine
FL Ð Fusible Link
FLW Ð Fusible Link Wire
FRT ÐFront
FWD Ð Front Wheel Drive
4WD Ð Four Wheel Drive
4x4 Ð Four Wheel Drive
4 A/T Ð Four Speed Automatic Transmission/Transaxle
Gal Ð Gallon
Gen Ð Generator
Gov Ð Governor
g Ð Gram
Harn Ð Harness
HC Ð Hydrocarbons
HD ÐHeavy Duty
HEI Ð High Energy Ignition
Hg Ð Mercury
HiAlt Ð High Altitude
HVAC Ð Heater-Vent-Air Conditioning
IAC Ð Idle Air Control
IC Ð Integrated Circuit
ID Ð Identification
Ð Inside Diameter
IDI Ð Integrated Direct Ignition
IGN Ð Ignition
ILC Ð Idle Load Compensator
INJ ÐInjection
IP Ð Instrument Panel
IPC Ð Instrument Panel Cluster
INT Ð Intake
J/B Ð Junction Block
km Ð Kilometers
km/h Ð Kilometer per Hour
kPa Ð KiloPascals
KV Ð Kilovolts (thousands of volts)
KW Ð Kilowatts
0AÐ12 GENERAL INFORMATION

0BÐ2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
GASOLINE ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
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610
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1215
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1820
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2425
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3030
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3635
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4240
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4845
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5450
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6055
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6660
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7265
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7870
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8475
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9080
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9685
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10290
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10895
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114100
60
120
GASOLINE ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
* Timing belt
Spark plugs (For leaded fuel use)
Spark plugs (For unleaded fuel use)
Exhaust system
Radiator coolant concentration
Cooling system for water leakage
All hoses and pipes in engine compartment
for clog or damage
Fuel filter
Fuel leakage
Fuel tank
* Air cleaner element
Pre air cleaner
Engine drive belt
Valve clearance
O
2 Sensor (For leaded fuel use)
O
2 Sensor (For unleaded fuel use)-
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(Replace every 165,000 km or 100,000 miles)
(Replace every 165,000 km or 100,000 miles)
(Check and adjust if necessary every 100,000 km or 60,000 miles)
(Replace every 150,000 km or 90,000 miles)
CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid leakage
*
(1)Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
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Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)
FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
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ATATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
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(1): Adjust or change automatic transmission fluid.
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”.

0BÐ4 MAINTENANCE AND LUBRICATION
DIESEL ENGINE MODELI: Inspect and correct or replace as necessary A: Adjust
R: Replace or change T: Tighten to specified torque L: Lubricate
SERVICE INTERVAL: x 1,000 km
(Use odometer reading x 1,000 miles
or months whichever comes first) or months5
3
610
6
1215
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1820
12
2425
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3030
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3635
21
4240
24
4845
27
5450
30
6055
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6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
DIESEL ENGINE
* Engine oil
* Engine oil filter
Oil leakage and contamination
Idling speed and acceleration
Fan belt tension and damage
Timing belt
Exhaust system
All hoses and pipes in engine compartment
for clog or damage
Valve clearance
* Air cleaner element
Fuel filter
Radiator coolant concentration
Cooling system for water leakage-
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NOTE: In the 4JXI-TC diesel engine, there is provided sub (2nd) oil filter for fuel injection at the upper part of crank case on the left
side of the engine. This oil filter maintenance-free and does not need a periodic replacement. See reverse side the (back)
cover for installation location of the sub (2nd) oil filter.(Replace every 200,000 km or 125,000 miles)
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”. CLUTCH
Clutch fluid
Clutch pedal travel and free play
TRANSMISSION OR TRANSMISSION WITH
TRANSFER CASE
* Manual transmission with transfer case oil
* Automatic transmission fluid
* Transfer case oil
PROPELLER SHAFT
Loose connections
* Universal joints and splines for wear
Universal joints and sliding sleeve (front and rear)FRONT AND REAR AXLE
* Differential gear oil (Front and rear)
Shift on the fly system gear oil
Front axle shaft rubber boot for damage
Axle case for distortion or damage
Axle shafts for distortion or damage-
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ATAT
STEERING
* Power steering fluid
Oil leakage
* Steering system for looseness or damage
Power steering hose
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
SERVICE BRAKES
Brake fluid
Brake system for fluid leakage
Brake function
* Disc brake pads and discs wear
Brake pedal travel and free play
Pipes and hoses for loose connections or damage
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0BÐ8 MAINTENANCE AND LUBRICATION
FLUID TYPE
Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade
LUBRICATION MAKE BRAND / TYPEGRADE
API ACEA
ISUZU GENUINE BESCO ATF II, ATF III
EXXON / ESSO ESSO ATF D (DEXRONÒ
II-D)
Automatic transmission MOBIL MOBIL ATF (DEXRONÒ
III)
Power steering CALTEX ATF HD (DEXRONÒ
II)
SHELL SHELL DONAX TA (DEXRONÒ
II-D)
ELF ELFMATIC G3 (DEXRONÒ
III)
TOTAL TOTAL FLUID IID (DEXRONÒ
II-D)
ISUZU GENUINE
BESCO L-2 GREASE (No.2), L-3 GREASE (No.3)Propeller shaft sliding EXXON / ESSO RONEX MP (No.2)
yoke, Universal joint MOBIL MOBILGREASE HP 222 (No.2)
Grease fittingCALTEX / TEXACOSTARPLEX-2 (No.2)
(General purpose grease)SHELL SHELL RETINAX A (No.2)
TOTAL MULTIS EP2, EP3 (No.2, No.3)
Propeller shaft slidingISUZU GENUINE ONE LUBER MO GREASE
yoke EXXON / ESSO BEACON Q2 (No.2)
Universal joint EXXON / ESSO MULTIPURPOSE GREASE (Moly) (No.2)
General purpose greaseCALTEX MOLYTEX GREASE EP2 (No.2)(in Molybdenum)TOTAL TOTAL MULTIS MS2 (No.2)
ISUZU GENUINE BESCO LLC SUPER TYPE E
TEXACO / CALTEX HAVOLINE EXTENDED LIFE ANTIFREEZE
Engine cooling system COOLANT
HAVOLINE XLC
EXTENDED LIFE COOLANT 6280
NOTE:
When the recommended lubricants are specified in the workshop manual, follow them.

00 Ð 16 SERVICE INFORMATION
TROUBLE POSSIBLE CAUSE CORRECTION
HEATING CYCLE TROUBLESHOOTING
No heating or
Insufficient heating.·Refer to ÒFAN CONTROL KNOB (FAN
SWITCH)Ó Troubleshooting.
·Check the engine coolant temperature
after warming up the engine and check
the thermostat. Replace as necessary.
·Add engine coolant as required.
·Check if the water hose to the heater
core is clogged, collapsed or twisted.
Repair or replace as necessary.
·Check water pump function. Repair or
replace as necessary.
·Clean or replace as necessary.
·Repair the temperature control link unit
or mode doors.
·Repair or adjust the control cables.
·Repair or replace as necessary.
·Refer to ÒCERAMIC HEATERÓ
Troubleshooting.
·Repair.
·Repair.
·Repair.
·Adjust. 1. Blower motor does not run, or
runs improperly.
2. Engine coolant temperature is
low.
3. Insufficient engine coolant.
4. Circulation volume of engine
coolant is insufficient.
5. Heater core clogged or
collapsed.
6. The heater core is not provided
with air sent from the blower
motor.
7. Duct connections defective or
unsealing.
8. Ceramic heater defective.
1. Cable attaching clip is not
correct.
2. Link unit of heater unit or
blower assembly defective.
1. Link unit of heater unit or
blower assembly defective
2. Control cable is not adjusted. Control knob moves
but mode door does
not operate.
The mode door
cannot be set to the
mode selected.

SERVICE INFORMATION 00 Ð 27
MAGNETIC CLUTCH
When the A/C switch and the fan control knob (fan
switch) are turned on with the engine running,
current flows through the thermostat and the com-
pressor relay to activate the magnetic clutch.
The air conditioning can be stopped by turning off
the A/C switch or the fan control knob (fan switch).
However, even when the air conditioning is in oper-ation, the electronic thermostat, the pressure switch
or the PCM (6VD1/6VE1 Engine) is used to stop the
air conditioning temporarily by turning off the mag-
netic clutch in the prearranged conditions to reduce
the engine load which is being caused by the rise in
the engine coolant temperature, and the accelera-
tion of the vehicle, etc.
123
45 6
RELAY; A/C
B-36C-20
10A
A/C FL-1
80A
MAIN
1
2
B-2
C-25
2
4
X-5
1
3 (3)
(1)
4
13
24
1
A/C SW.
FAN SW.
I-23
PRESSURE
SW.
RELAY;
THERMOSTAT
B-2
X-7 C-25
C-1C-3E-3I-23
BATTERY
X-7
RELAY: A/C
COMPRESSOR
1
E-3
MAGNETIC
CLUTCHMg
OFF
I-18
2
6
1
321123
12
3412
11
213
5 46
I-18
X-5
B-1(LHD) (RHD)
B-1
1
2 34
W/ CONDENSER
FAN
2
4
1
3
C-3PCM (E15)
C-1PCM (B14)
3
1
2
ELECTRONIC
THERMOSTAT
I-42
I-42B-36
Pin number with ( ); RHD
A1 A2 A3 A4 A5 A6 A7 A8 A9A10 A11 A12 A13 A14 A15 A16B1 B2 B3 B4 B5 B6 B7 B8 B9B10 B11 B12 B13 B14 B15 B16E1 E2 E3 E4 E5 E6 E7 E8 E9E10 E11 E12 E13 E14 E15 E16F1 F2 F3 F4 F5 F6 F7 F8 F9F10 F11 F12 F13 F14 F15 F16
6VD1/6VE1 ENGINE
D08RY00295

When the engine warming up, the warmed engine
coolant is sent out into the heater core. The heater
system supplies warm air into the passenger
compartment to warm it up.
Outside air is circulated through the heater core of
the heater unit and then back into the passenger
compartment. By controlling the mixture of outside
air and heater core air, the most comfortable
passenger compartment temperature can be
selected and maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature
control knob. This knob acts to open and close the
air mix door, thus controlling the amount of air
passed through the heater core.The air select knob, with its different modes, also
allows you to select and maintain the most
comfortable passenger compartment temperature.
The air source select lever is used to select either
ÒFRESHÓ for the introduction of the outside air, or
ÒCIRCÓ for the circulation of the inside air. When
the lever is set to ÒFRESHÓ, the outside air is always
taken into the passenger compartment. When
setting the lever to ÒCIRCÓ position, the circulation
of air is restricted only to the inside air with no
introduction of the outside air and the air in the
passenger compartment gets warm quickened.
However, the lever is normally set to ÒFRESHÓ to
prevent the windshield from clouding.
1A Ð 2 HEATING AND VENTILATION
GENERAL DESCRIPTION
HEATER
Side def hose
Vent box
Upper center vent duct
Lower center
vent ductBlower assembly
Control lever assembly Evaporator
assembly W/A/C
W/O A/C
Duct Heater unit
Lap vent nozzle Vent box Side def hoseDefroster nozzle
Rear heater duct
A/C - Air Conditioning This illustration is based on LHD

Full hot switch Ceramic heater Heater unit
HEATING AND VENTILATION 1A Ð 5
CERAMIC HEATER
When the fan control knob (fan switch) turns on with the temperature control knob set to ÒFULL HOTÓ (full
hot switch ÒONÓ), the ceramic heater in the heater unit gets hot, thus causing the heater blow temperature
of diesel vehicle to get high to improve the heating performance (Since the engine coolant temperature of
diesel vehicle is low, its blow temperature is also low.).
Glow plug
Full hot switch
Fan switch
Thermo switch
Less than 80¡C (177.8¡F)
CERAMIC HEATER
ÒONÓCERAMIC HEATER
ÒOFFÓ
OFF
ON
OFF
OFF
OFF
ON
ON
ON
This illustration is based on RHD

HEATING AND VENTILATION 1A Ð 7
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following points:
1. When handling the ECM and the control unit, be
careful not to make any improper connection of the
connectors.
2. Adjust control lever assembly cables.
Refer to ÒCONTROL LEVER ASSEMBLYÓ installation
steps in this section.
3. When installing the heater unit, defroster nozzle and
center vent duct, be sure that proper seal is made,
without any gap between then.
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Drain engine coolant
·Discharge and recover refrigerant (W/A/C)
(Refer to Section 1B ÒREFRIGERANT RECOVERYÓ)
1. Instrument Panel Assembly
Refer to Section 10 ÒBODYÓ for INSTRUMENT PANEL
ASSEMBLY removal procedure.
2. Water Hose
Disconnect water hoses at heater unit.
3. Resistor Connector
4. Duct
4a. Evaporator Assembly
Refer to Section 1B ÒAIR CONDITIONINGÓ for
Evaporator Assembly removal procedure.
5. Instrument panel center bracket
6. Rear Heater Duct
7. Heater Unit
8. Lap vent nozzle
9. Center ventilation lower duct

HEATING AND VENTILATION 1A Ð 9
REMOVAL
Preparation:
·Disconnect the battery ground cable
·Drain engine coolant
1. Heater Unit
Refer to ÒHEATER UNITÓ removal procedure in this
section.
2. Duct
3. Case (Mode Control)
Do not remove link unit at this step.
4. Case (Temperature Control)
Separate two halves of core case.
Heater core
5. Heater Core
Heater core
6. Mode Door
Pull out the mode door while raising up the catch of
the door lever.
INSTALLATION
To install, follow the removal steps in the reverse order,
noting the following point:
1. Check that each mode door operates properly.