maintenance ISUZU TROOPER 1998 Service Repair Manual

PAGE NEXT
THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
0A General Information
0B Maintenance and Lubrication

GENERAL INFORMATION 0AÐ3
HOW TO USE THIS MANUAL
1. Find the applicable section by referring to the
table of contents on the introduction page of
each manual.
2. In ÒService InformationÓ, an opening section of
each manual, the troubleshooting, maintenance
servicing, service data and/or information on
special tools required for the service operations
described in the next subsequent sections are
arranged and compiled so concisely that you
can see at a first glance.
3. Each section except the Service Information
section is basically arranged in the following
order of headings:
General description
On-vehicle service
Unit repair4. The service operations are in two groups: one is
the ÒOn-vehicle serviceÓ where operations can
be directly performed on the vehicle, and the
other is the ÒUnit repairÓ where the operations
are done on the work bench after removing the
unit from the vehicle.
5. Each service operation section begins with a
disassembled view of unit or equipment, which
is useful to find relative components, service
procedure, availability and contents of repair
kits, etc.
The number represents sequence of
removal or disassembly
Removal of unnumbered the parts
(excluding bolts, nuts, washers,
gaskets, cotter pins, etc.) is
unnecessary unless replacement is
needed.
Where parts replacement requires
specific information, instructions are
given in ÒInspection and RepairÓ.
This frame is to be removed as a
large disassembly with all the parts
assembled in the frame. Each one of
the parts in the frame is removed as
a small disassembly.
Parts to be removed or installed as a
unit.
H Parts contained in repair kit.
H Indicates repair kit availability.
When the installation (reassembly)
procedure is the reverse order of the
removal (disassembly) procedure,
the sequence of service operation
and the parts names will be omitted.
Name of parts listed in sequence of
service operation.

MAINTENANCE AND LUBRICATION 0BÐ1
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
PAGE
Maintenance Schedule...................................................0BÐ 2
Recommended Fluids, Lubricants and Fuels.................................0BÐ 7
Oil Viscosity Chart.......................................................0BÐ10
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners
or fasteners joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.

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
6
1215
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1820
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2425
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3030
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3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
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
*
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”.

MAINTENANCE AND LUBRICATION 0BÐ3
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
3
610
6
1215
9
1820
12
2425
15
3030
18
3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
PARKING BRAKE
Parking brake function
Parking brake lever travel
Cables for looseness or damage and guide for
damage
Ratchet for wear or damage
SUSPENSION
Spring leaves for damage
Mount for looseness or damage
Shock absorbers for oil leakage
Shock absorbers mount for looseness
Rubber bushes of suspension wear or damage
Spring action for loss of balance due to weakeningJoint ball rubber boot for damage
WHEELS
Wheel pins
Wheel disc for damage
Hub bearing grease
Front and rear hub bearings for looseness
Tire pressure and damage
Tire rotation
OTHERS
Bolts and nuts on chassis and body
Lube front free-wheeling hubs-
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(Rotate as required)
*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
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1215
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1820
12
2425
15
3030
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3635
21
4240
24
4845
27
5450
30
6055
33
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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MAINTENANCE AND LUBRICATION 0BÐ5
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
9
1820
12
2425
15
3030
18
3635
21
4240
24
4845
27
5450
30
6055
33
6660
36
7265
39
7870
42
8475
45
9080
48
9685
51
10290
54
10895
57
114100
60
120
PARKING BRAKE
Parking brake function
Parking brake lever travel
Cables for looseness or damage and guide for
damage
Ratchet for wear or damage
SUSPENSION
Spring leaves for damage
Mount for looseness or damage
Shock absorbers for oil leakage
Shock absorbers mount for looseness
Rubber bushes of suspension wear or damage
Spring action for loss of balance due to weakeningJoint ball rubber boot for damage
WHEELS
Wheel pins
Wheel disc for damage
Hub bearing grease
Front and rear hub bearings for looseness
Tire pressure and damage
Tire rotation
OTHERS
Bolts and nuts on chassis and body
Lube front free-wheeling hubs-
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(Rotate as required)
*Marks: Under severe driving conditions, additional maintenance is required.
Refer to “Maintenance schedule under severe driving conditions”.

0BÐ6 MAINTENANCE AND LUBRICATION
Item IntervalCondition
ABCD A+D
Engine oil G : Change every 5,000 km (3,000 miles)
D : Change every 5,000 km (3,000 miles) ll
Engine oil filter G : Replace every 10,000 km (6,000 miles)
D : Replace every 5,000 km (3,000 miles) ll
Air cleaner element G : Replace every 20,000 km (12,000 miles)
D : Replace every 40,000 km (25,000 miles)l
Power steering fluid Replace every 50,000 km (30,000 miles)ll
Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)l
Universal joints and sleeves Inspect for wear and lubricate every 7,500 km (4,500 miles)ll
Transmission with MT Change every 20,000 km (12,000 miles)
transfer case oil after changing at initial 10,000 km (6,000 miles)l
Transmission :
AT
Change every 32,000 km (20,000 miles) lll l
Transfer:
TF Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)l
Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 5,000 km (3,000 miles) l
Disc brake pads and discs Inspect every 5,000 km (3,000 miles)lll
Timing belt G : Replace every 120,000 km (75,000 miles)ll
EXPLANATION OF COMPLETE VEHICLE MAINTENANCE SCHEDULE
Explanations of the services listed in the proceeding
Maintenance Scheduled are presented in ÒService
InformationÓ section of each manual.Replace all questionable parts and note any
necessary repairs as you perform these
maintenance procedures.
MAINTENANCE SCHEDULE UNDER SEVERE DRIVING CONDITIONS
Severe driving conditions
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or salted roads

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

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.